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user-friendly interface design and development for continuous

1. 4 4 4 hk 4 Gai K Mm KN a a a LULU ssauyary 498 XN 4 Distance Below Meniscus mm 4 k 4 k 4 fina S ee a H Sc cea iar va 4 dsolid E AO O VAART as TA EI A AT A re TO RRR SSS SSS SSS SSS SPSS rad AB dliquid K a Se ee CI a a Re tenO a CH a ui ssauuaiu 194671 Ynja K a Distance Below Meniscus mm Figure C 2la Flux layer thicknesses and heat transfer out gpt for the mold simulation 95 12000 AZ VW MK 19191902 J9JSUBJ JLo H DO 1001 __ __ 3000 DO 401 T I I I I I I I I I I I I I I I I I I I I I I I L I I I I I I I I I I I I I I I I I I I I I I I I I I T I I I I I I I I I I I I I I I I I I I I I I I L I I I I I I I I I I I I I I I I I I I I I I I I I I T I I I I I I I I I I I I 00 21 Distance Below Meniscus mm 300 0 A 250 0 T os A T oe oe A viscosity fasiod NSOISIA 150 0 SEE RE I D ee 100 0 ALE RL IA III IRR 50 0 DIAL PRA A A er TT Distance Below Meniscus mm Figure C 21b Flux layer thicknesses and heat transfer out g
2. x a E e E a0 ape e m m e e m e ee eee ee eee eee eee eee eee ee ee eee tooo a a a bobo a a a N 60 A pT 40 m m m m m m m m s d T ee T ec Coen 20 Distance Below Slab Surface mm Me L 14925 4 1492 5 A a 1492 5 m m m m m m m m m PE T E TT 1492 5 1492 5 9 ainjesadway snpijos Distance Below Slab Surface mm Figure D 17b Secondary dendrite arm spacing and solidus temperature from segregation parameters out seg for full caster simulation 133 10 00mm below surface Phase Fraction Temperature C h Delta Gamma E Alpha _ Temp 2000 4000 6000 3000 10000 12000 14000 Distance Below Meniscus mm Shell Surface Phase Fraction Temperature C 2000 4000 6000 8000 10000 12000 14000 16000 Distance Below Meniscus mm HF Liquid amp Delta Gamma _ Alpha Temp mm T E 10 00mm below surface Shell Surface Position 0 0 10 0 20 0 1522 6 1 000 0 000 0 000 0 000 14391 0 000 0 867 0 133 0 000 40 0 Figure D 18 Phase fractions out frc for full caster simulation 134 A 9 aimes dwa L 1510 1505 15
3. La Mold thickness with water channgl Figure 5 5 Water channel parameters in the mold 13 Mold Cooling Water Parameters Cooling water temperature at mold top Cooling water pressure Cooling water velocity or flowrate Cooling water 7 800 7 800 Cooling water from mad top to bottom Cooling water from mad bottom to top Mold Water Properties Heat transfer coefficient le Default Enter Value Water heat capacity i Default Enter Value 4179 000 JAK Figure 5 6 Mold properties parameters for mold simulation 39 Mold Geometry Funnel height 0 000 Funnel width 0 000 Funnel depth at mold top 0 000 mm Machine outer radius 11 760 m Machine inner radius 11 985 m water channel 51 000 Equivalent thickness of water box 30 000 Mean temperature diff between hot amp cold face of NF 1 000 WE 25 000 5 000 5 000 rem Channel distance center to center 20 000 29 000 rom En mi Narrow face NF mold thickness with ro 7 gt A i S T y Total channel cross sectional area sil sn 315 000 315 000 MaS 1 60E 05 Figure 5 6 cont Mold properties parameters for mold simulation Mold thermal conductivity Mold thermal expansion coeff Mold Coating Plating Thickness Number of mold coating plating thickness changes down mold ACC P 0 550 72 100 6 000 1 000 0 060 PAPA o PAS av 001 100 0 10 0 00 0 00 0 000 0 00 0 00 400
4. NF Dstr Mold Dstr EndWall Deflection mm 400 600 600 Distance Below Meniscus mm deal Tpr Inst deal Tpr Cumul E T la nt a TE H T a 2 400 600 500 Distance Below Meniscus mm Figure D 14b Taper histories out tpr for full caster simulation 127 Output Heat Transfer History in Spray Zones below Mold 4 hnconv hrad hspray hconw2 htot TTT vibo oo TITO LI TNT 5 i H ni z ML l i Ifill LAT ELSA HI RA LALA i TA areal afl Ri BANE ra oF i AE 1 MA f PELEA A tal hus b VAL IK wee i J fat rer eat I i il i EFA LTF ARE Ll J E z E cn L E o La 2 wn E i TE a lt 2000 4000 6000 8000 10000 12000 14000 16000 Distance Below Meniscus mm S U 86 187 33 870 E 192 1 1036 47 _ al 860 co co o ca fan ae Se ih Pa oo mm Pa I AAA bd bed bd ed SE bree 99 CO oo im LO RS a o oo ay S o aoa ayaa a oa LL Po Ea SIE sl Figure D 15 Spray zone heat transfer out spr for full caster simulation 128 Thermal Conductivity VWmkK 600 FOO 800 900 1000 1100 1200 1300 1400 1500 1600 Temperature C Specific Heat k J kg K 1000 1500 2000 Temperature C SN os y nal Ti dba del al a rk tle fa fg ra 4 SEE ooo 0 00 Se om amoo T omj aa e e ail e a
5. 0 250 870 25 0 0 00 0 50 1 00 100 100 1 00 0 250 870 25 0 0 00 0 50 1 00 100 100 1 00 0 250 870 25 0 0 00 0 50 1 00 100 100 __ 1 00 Figure C 4b Spray zone properties for mold simulation 71 Mold Cooling Water Parameters Cooling water temperature at mold top Cooling water pressure Cooling water velocity or flowrate 0 202 TFS Cooling water 7 800 7 800 Cooling water from mod top to bottom Cooling water from mad bottom to top Mold Water Properties Heat transfer coefficient Cefault Enter Value N MAA rrr Water heat capacity Enter Value 4179 000 JA kg Water density I Default Enter Value 995 600 Mold Geometry Funnel height Funnel depth at mold top Machine outer radius Machine inner radius Narrow face NF mold thickness with water channel 51 000 Equivalent thickness of water box 20 000 Mean temperature diff between hot amp cold face of NF 1 000 5 000 5 000 mm Channel distance center to center 20 000 29 000 Total channel cross sectional area se I Mold thermal conductivity 315 000 315 000 WYO Mold thermal expansion coeff 1 60E 05 Figure C 5 Mold properties parameters for mold simulation 12 PARA mmr an TRATTA toor 00 000 000 f 000 400000 3 0 01 100 0 10 0 00 Distance below meniscus me Figure Thermocouple Pea S for mold simulation Flux mold or shell mold IEA conta
6. Shell face to consider Mold type Mold face to consider Do you want 2D calculation in mold Max Distance below meniscus for 2D 800 000 i calculation 800 000 Time increment 5 Number of Slab sections Printout interval 10 000 Max Simulation Thickness Max number of iterations 1000000 Shell nidi i below hot 3 Fraction solid for shell thickness location Is superheat treated as heatflux es defaut 2D calculation qive more accurac Do you want to print all files for related information for each slice Z distance for heat balance Figure 5 3 Simulation parameters for mold simulation 35 The superheat can be treated via three different options Choosing no or yes default to Is superheat treated as a heat flux does not require any more input from the user The option yes enter data will prompt a button linking the user to a table and graph where the user must enter the super heat flux as a function of distance below the meniscus It is expected that this data should have come from the results of a fluid flow simulation This example simulation uses the yes default option which takes this data from a database of typical profiles from past fluid simulations and adjusts the profile according to the casting speed the superheat temperature difference and the mold face being modeled 8 5 2 2 Steel Slab Properties The next input page is the steel slab properties worksheet For this example the steel slab
7. old hot face Steel surface E E d 300 Distance Below Meniscus mm Figure 5 14 Flux temperature graph from the mold simulation example 46 There are also outputs such as the shell temperatures shell thicknesses shear stress in the gap phase fractions and many more that are shown in Appendix C for this mold simulation 5 3 Complete Caster Simulation Example The complete caster simulation demonstrates how the user interface can be used to conduct a simulation through CONID using spray zone parameters to calculate heat transfer in the spray region 5 3 1 Casting Conditions For this particular full caster simulation the casting speed 1s constant and set to 3 9878 m min and the casting conditions parameters are entered as shown in Figure 5 15 The heat flux profile average heat flux and cooling water temperature increase options for shell mold interface heat transfer option all link the user to tables and graphs to enter data to visualize the data For this example full caster simulation the Enter Heat Flux Data option was chosen and the data is entered as shown in Figure 5 16 The data entered creates a piecewise heat flux graph as a function of distance below the meniscus in the mold Enter Casting Speed 3 9079 TV nP m Update spray zones M waring Casting Speed Tram spray table Pour Temperature 1553 000 mom Distance of Meniscus from top of mold 100 000 oe Nozzle submergence depth
8. Concentrzion 1 Sal Concentrzion 2 Si Figure 3 3 Homepage at startup of program The input buttons and the Final Data Check are colored in blue and listed in suggested order Blue conveys to the user to click on the button The Interface button color depends on the choice made for the shell mold interface heat transfer option If the shell mold interface heat transfer is set to flux casting or oil casting then the Interface button will turn blue also otherwise it will be gray This 1s to help users understand that the input data on the interface page is not necessary unless certain options are chosen After clicking the Final Data Check the 14 inputs buttons will turn either green or yellow to signify 1f that worksheet passed the data check If no data 1s entered for a parameter it will fail the Final Data Check and the button of the input worksheet and the description of the parameter will turn yellow to show the user where to find the location of the problem A green button signifies that the user has already passed the step and can move onto the next blue step If all data passes the data check then the Write Input File button will turn blue to suggest moving to the next step of running the program and later post processing 3 4 Features In creating the new interface several features were added to provide extra functionality not possible with the old interface The input graphs grade table spra
9. NF mold thickness with water channel mm 40 00000 Equivalent thickness of water box mm 1 000000 Mean temperature diff between hot amp cold face of NF C 20 00000 20 00000 Cooling water channel depth mm WF NF 5 000000 5 000000 Cooling water channel width mm WF NF 20 00000 22 00000 Channel distance center to center mm WF NF 8300 000 400 0000 Total channel cross sectional area mm 2 WF NF served by water flow line where temp rise measured 350 0000 350 0000 Mold thermal conductivity W mK WF NF 1 6000000E 05 Mold thermal expansion coeff 1 K 0 0000000E 00 funnel height mm 0 0000000E 00 funnel width mm 0 0000000E 00 funnel depth at mold top mm 3 500000 Machine outer radius m 3 500000 Machine inner radius m 2 Number of mold coating plating thickness changes down mold No Scale Ni Cr Others Air gap Z positions unit 1 0 000 0 000 0 000 0 000 0 000 0 000 mm 2 0 000 0 000 0 000 0 000 0 000 850 000 mm 0 550 72 100 67 000 1 000 0 050 Conductivity W mK MOLD THERMOCOUPLES 0 0000000E 00 Offset distance towards hot face mm 45 Total number of thermocouples No Distance beneath Distance below hot surface mm meniscus mm 1 0 00 70 00 2 0 00 50 00 3 0 00 20 00 4 0 00 10 00 5 10 80 0 00 6 10 80 20 00 7 10 80 50 00 8 10 80 20 00 9 10 80 10 00 10 10 80 0 00 11 10 80 20 00 12 10 80 30 00 13 10 80 50 00 14 10 80 70 00 15 10 80 85 00 16 10 80 100 00 17 10 80 120 00 18 10 80 140 00 19 10 80 170 00 20
10. The interface also incorporates a check box titled Update spray zones from spray table which lets users choose if they want to use this spray table feature or not The spray table feature is very helpful in cutting down the amount of time users need to spend on creating input parameters for simulations 3 4 4 Units The input file for CONID uses all cgs type metric units as specified on the example input file Appendix A Although many plants in other countries use similar units as CONID most U S plants use the English Units System or a mix of different unit systems The usability of this software is very low for users that work mainly with the English Units System They have to convert almost every parameter from their familiar English Units into unfamiliar Metric Units Industry researchers and engineers using the English Units have such great usability problems with CONID that they mainly will not use the software for this specific reason The new interface incorporates a change of units feature to increase the usability of CONID significantly for this important group of users The units are also customizable to let each steel company setup the units with the customized mix of mks Metric cgs Metric and English units used at their plant There are three different sets of units the user can choose from the homepage Metric British and Custom The Metric Units are set to be similar to the CONID units and the English Units are set to be the m
11. The program automatically creates the zone numbers If using spray tables the Plant Zone Name on the spray zone worksheets must correspond to the correct spray zones names listed in the spray table worksheet The Plant Zone Name does not copy from the inner radius to the outer radius to allow for spray tables with different spray zones on the inner and outer radius The user must set the Plant Zones Name on both the inner and outer radius spray zone pages The spray zones start distances and number of support rolls in each zone are defined in CONID as shown in Figure 5 21 Each zone starts in the middle of the last roll in the previous zone The z1 z2 z3 hl h2 and h3 are factors for which the heat transfer coefficient generated by the impact of the spray water profile from each nozzle can be defined from experimental measurements as Figure 5 22 demonstrates In many cases the inner and 52 outer radius spray zone information 1s the same or very similar The user can click on the Copy Spray Zone to Outer Radius to copy the spray zone data including the Leidenfrost effect data the Nozaki equation parameters and spray zone table to the outer radius If different outer radius parameters are desired they can be set on the spray zone outer radius worksheet independently The inner radius spray zones for this full caster simulation are shown in Figure 5 23 mold mold exit start of zone 1 1 roll zone start of zone
12. Where Teon1a 18 the value of the temperature in CONID units which is Celsius Tinput 1s the temperature displayed in the unit chosen by the user Faddition 18 the added constant factor and Fmultiplication 18 the multiplication factor Both of these factors are entered into the same cell for the conversion of temperature units separated by a comma F multiplication Faddition The units label is entered in the cell to its immediate left For example to use Fahrenheit as the custom unit enter F In the Custom unit set column and then enter 0 55555 32 in the Factor to multiply by column for the custom unit set 21 s e EA A RA A eee A CI Home Unit set Names Metric British Custom_ Le hits 4 Factor to Multiply Factor to Multiply Factor to Multiply Mame Metric by to Convert to British by to Convert to Custom by to Convert to a Con1D units Con1D units Con1D units B Temperature 100000 0 55555 32 1 00000 0 3 Distance J mm 1 in 254 Custom 1 _ 410 Heat Flux Data Points kita Btusihreftaa 0 003154 verage mold heat flux NMV Btuifhreft 2 0 000003154 Mold cooling water temp 12 Increase L 1 00000 F 0 55555 Custom 1 00000 Super Heat Flux kine Btus hrft 2 0 003154 Factor to Multiply special menu for casting Casting by to Convert to speed speed Con D units 0 0254 Factor to Multiply special menu for varying Casting by ta Convert to casting speed time speed Time Con U units s
13. consistency 1s believed to be critical in achieving a usable interface The interface aims to provide clear exits when needed There are home buttons located in the same location of the worksheet throughout the interface This allows a user to exit back the homepage from any worksheet The options that may write over data such as updates from the spray table and grade table always warn the user before overwriting information The users can then cancel and exit the procedure from the warning message if desired The grade table and spray table present significant shortcuts for experienced users With the use of the spray table experienced users can change the casting speed and water flow rates in spray zones by only changing the casting speed The grade table offers experienced users the ability to setup preset grades that can be chosen quickly without having to enter the composition data manually The interface incorporates helpful error messages If the CONID executable file is not found in the working directory then a message tells the user of the problem and also how to fix it If a user enters a different number in the slab thickness from the max simulation thickness the program notifies the user and also describes what to do to fix it The final data check tries to help prevent errors from missing data CONID will simply crash with no feedback 1f there 1s data missing To prevent this from happening the final data check was implemented A de
14. information for each slice Z distance for heat balance Figure D 3 Simulation parameters for full caster simulation 110 WF Mold Thickness with water channel outer rad top WE Mold Thickness with water channel inner rad top S 0 0020 CK Simple Seg Model Steel Liquidus Temp 150 steel Density at Enter value 7 00 __ Steel Heat of Fusion Y Osta Steet Emissivity P Data Steel Specific Heat Fosas Steel Thermal Conductivity Iv Default Enter Value Steel Thermal expansion Coeff i Default Enter Value 1 30E 05 Figure D 4 Steel slab properties for full caster simulation 111 ISPRAVZONES Inner Bagig Patten ide Spray Table Spray Zone Pattern p from spray table h multipliers Temperatures 500 600 zooj s00 900 Water and ambient temperature after spray zone A for Nozaki A 0 3925 c for Nozaki c 0 55 b for Nozaki b 0 0075 Number of Spray Zones End of last spray zone 11246 0 Plant Zone Zone Zone Number Roll Water Spray Spray Contact ds rid Name Number Starts atl of Rolls Radius flowrate width Length angle q ew E IA zc 3 17670 6 0 062 150 139 0 987 0 050 10 00 0 220 2828 0 2 za 6 59040 10 0 095 57 532 1680 0 050 10 00 0 360 Figure D 5a Spray zone properties for full caster simulation Ambient e MM 0 250 8 70 250 0 05 0 50 0 95 0 60 150 0 60 0 250 so
15. inner rad top STEEL PROPERTIES 0 0500 1 5200 0 0150 0 0120 0 3400 C GG Mn PS P Si 0 0000 0 0000 0 0000 0 0000 0 0000 Cr Ni Cu Mo Ti 0 0000 0 0000 0 0000 0 0000 0 0000 AI WV WN WNb VW 0 0000 Co additional components 1000 Grade flag 1000 304 316 317 347 410 419 420 430 999 1 If CK simple Seg Model wanted for default Tliq Tsol 1 yes 0 no 10 000 Cooling rate used in Seg Model if above 1 K sec Override defaults with following constants 1 default 1 00 Steel liquidus temperature C 1 00 Steel solidus temperature C 1 00 Steel density g cm 3 7000 1 00 Heat fusion of steel kJ kg 243 1 00 Steel emissivity 1 00 Steel specific heat kJ kg deg K 0 680 1 00 Steel thermal conductivity W mK 1 00E 00 Steel thermal expansion coeff K 3 Parameters to update when model is calibrated ISIMULATION PARAMETERS 1 0 20 000 0 0 2 1 6 0 00 170 00 1 800 000 2 00E 03 460 Which version of Conl d to run 1 OFF version 1 ON version CONONLINE New simulation or Restart O new l restart Z distance for heat balance mm Which shell to consider 0 wide face 1 narrow face What type of mold O slab 1 funnel 2 billet 1 shell only Which moldface to consider 1 curved 2 straight Is superheat treated as heatflux 0 no 1 yes take default 1 yes enter data Number of zmm and q data points if above 1 Next 2 lines contain zmm mm and q kW m2 data 25 00 480 00 780 00
16. oi 39 00 0898 4 890E 03 0 00 0 00 0 00 1568 1 3900 0 825 4 890E 03 0 00 0 00 0 00 Figure D 16a Steel vien out prp for full caster simulation 129 1000 Temperature C D TE la L a TPE a 1100 1300 Temperature C Figure D 16b Steel properties out prp for full caster simulation 130 1 0 mn 0 9 0 8 07 0 6 0 4 0 3 0 2 0 1 0 0 4 3 1400 1425 1450 1475 1500 1525 1550 Temperature E o TE bn LL i OL gt Alpha fa Gamma fg 8 Delta fd Liquid Fl Figure D 16c Steel properties out prp for full caster simulation 131 Segregation Related Params vs Dist below Shell Surface Local solidification time sec 20 40 60 80 Distance Below Slab Surface mm j PB ce Si o Distance Below Slab Surface mm Figure D 17a Local solidification time and cooling rate graphs from segregation parameters out seg for full caster simulation 132 Y I I I I I I I I I I I I I I I I I I F I I I I I I I I I I I I I I I I I I EF I I I I I I I I I I I I I I I I I I F I I I I I I I I I I I I I I I I I I L I I I I I I I I I I I I I I I I I I 150 160 140 120 100 un buseds wiy apipuag Ap pU 0719 6 e E
17. or a customized mixture The interface integrates with a familiar spread sheet post processor which reads in the many output files generated by CONID and plots the results in readily customized graphs User feedback was used to make iterative improvements to the system The interface has received positive feedback from users The added user friendly features of the interface will allow a wider audience of users to benefit from the CONID model including both researchers and a larger group of users in the industrial environment of continuous casting systems 11 ACKNOWLEDGMENTS I would like to first thank my adviser Professor Brian G Thomas for his continuous support and technical expertise which helped to make this project a success I would also like to thank the students in Continuous Casting Consortium and the University of Illinois for their assistance with this project and their enduring friendship during my time in graduate school including Rajneesh Chaudhary Rui Liu Bryan Petrus Matt Rowan Varun Singh and Xiaoxu Zhou Finally I would like to thank my family for their continuous support and encouragement throughout the years 111 TABLE OF CONTENTS CHAPTER F INTRODUCTION cn a a cr obese eed oa a lil ween 1 A A A A A 1 ILZ COnUnious CASAS A A A A di 3 FES EOR D st e es ee o oleo rene re ess 4 CHAPTER2 BACKGROUND ille 6 A on III ogee II tn 6 D2 Pervious Mi e o o e Ds es el dt 6 ASS heads T eh ch Gav ced asc bec ns ae Se
18. then select Enable this content to enable the macros A high security setting in Excel 2003 can be changed to either a medium or low level by going to Tools Macro Security then choose either Medium or Low If the Options button does not show 12 up at start in Excel 2007 and the macros are not enabled then the security settings must be changed This can be done in Excel 2007 by clicking the Office Button Excel Options Trust Center Trust Center Settings then choose either Disable macros with notification or Enable all macros The security settings change is further described in the installation notes in Appendix B After changing the security settings the file must be reopened to allow for the initialization of the program Once the interface 15 open and macros are enabled the user will be directed to the homepage 3 3 Color Scheme The user interface follows a consistent color scheme for cells throughout the entire program in order to be user friendly The background was chosen to be gray to give a look of unimportance Cells that are colored white and bordered show the user where to enter information needed to setup the simulation Numbers in italics in these white cells show input data that has been suggested automatically based on choices elsewhere in the interface but which can be also overwritten by the user Gray text signifies that the parameter is not used for the simulation as a consequence of user choices of o
19. 000 0 00 0 00 800 000 Figure 5 7 Mold coating parameters for mold simulation 5 2 4 Thermocouples The thermocouples page defines the location of the thermocouples in the mold copper faces The predicted results at these locations can be compared against measured temperatures of thermocouples from the caster The first value to enter is the offset distance towards the hot face which is a calibration parameter that adjusts the mold location examined in order to predict temperatures in the real 3D mold geometry more accurately 4 12 13 Entering the total number of thermocouples up to 100 initiates the user interface to set the appropriate number of 40 boxes for entering in thermocouple data Specifically the user must enter in the distance beneath the hot surface and distance below the meniscus data for each thermocouple This example has four thermocouples with the distances set as shown in Figure 5 8 Offset distance towards hot face 0 00E 00 Total number of thermocouples Distance below meniscus Figure 5 8 a parameters entered for mold simulation 5 2 5 Interface Heat Transfer The interface heat transfer properties page 1s required if the user chooses to run a simulation where the shell mold interface heat transfer is calculated based on either flux casting or oil casting When choosing either of these two options the Interface button on the homepage will also turn blue similar to the other input buttons an
20. 1 3577 0 0049 0 0016 0 000 260 0 15 601 1510 90 0732 0732 0 000 00234 03250 14638 0 0067 0 0025 0 0000 Figure C 28 Solid phase concentrations 10 00mm below surface out sli for full caster simulation 108 APPENDIX D INPUTS AND OUTPUTS FOR FULL CASTER SIMULATION Enter Casting Speed TY FH Update spray zones M Varying Casting Speed mom spray table Pour Temperature 153 000 Distance of Meniscus from top of mold 100 000 Nozzle submergence depth 150 000 Max Simulation length 15000 00 Ae How to calculate shell mold Enter Heat Aux Data interface heat transfer CUI HERE and enter heat fix daa Into table Figure D 1 Casting condition parameters for full caster simulation Heat Flux Data Heat Flux 300 400 500 600 Z distance below meniscus Back to Casting London Medi Figure D 2 Heat flux data for full caster simulation 109 Shell face to consider Mold type Mold face to consider Do you want 2D calculation in mold 2D calculation give more accuracy Max Distance below meniscus for 2D calculation Time increment 5 Number of Slab sections Printout interval 10 000 soo Start output at 0 00E 00 Max Simulation Thickness I Default Enter Value 90 000 Max number of iterations 200000 Shell thermocouple number below hot 3 face Fraction solid for shell thickness location Is superheat treated as heatflux Do you want to print all files for related
21. 150 000 Max Simulation length 15000 00 SOLI How to calculate shell mold Enter Heat Aux Data interface heat transfer CUI HERE and enter heat five daa Into table Figure 5 15 Casting condition parameters for full caster simulation 47 Numbe Dist 3 3 Cefn 5360 0 3410 0 2600 0 2350 0 2340 0 2310 0 970 0 500 01 Heat Flux 300 400 500 600 Z distance below meniscus T ZDist ESA 0 00 ECTS A I Ss a ae gt EA ENS EA EA nni Back to Casting Condition Figure 5 16 Heat flux data for full caster simulation The 2D calculation in the mold option is only available if the shell mold interface heat transfer is set to either oil casting or flux casting Since heat flux data was chosen these parameters are set to gray text Super heat is treated as heat flux in this simulation by choosing the default and not entering super heat data The data entered for the simulation parameters 19 shown in Figure 5 17 5 3 2 Steel Slab Properties The steel slab properties are set in this simulation as shown in Figure 5 18 The steel slab is 90 mm thick and 1396mm wide The total mold length for this simulation is 950mm The steel is plain 0 06 wt carbon steel The grade flag set for this simulation is 1000 representing 1006 steel in this case The segregation model is used in this model with a cooling rate of 10 K sec The thermal and density properties of the steel are all set to default to let C
22. 2 Y 2 rolls start of zone 3 3 rolls start of zone 4 rollradw zone 4 i S Figure 5 21 Diagram of CONID spray zone configuration 13 53 h 0 z1 AB AE hi hy h spray A z2 AC AE h2 h h spray 23 AD AE h3 h h spray h 0 A B C D E Spray length Figure 5 22 Spray nozzle heat transfer coefficient characterization using z and h parameters 13 Patten poste spray zones L DU some be Spray Table Spray Zone Pattern Min convection heat transfer coeff natural Consider Leidenfrost Effect Number of Points on Leidenfrost Effect Curve Water and ambient temperature after spray zone A for Nozaki A 0 3925 c for Nozaki c 0 55 b for Nozaki b 0 0075 Add Delete Zanes 1 N spray AX Owner x 1 DX I spray Plant Zone Zone Zone Number Roll Water Spray Spray Contact sca d Name Number Starts at of Rolls Radius flowrate width Length angle q mr E ee 850 0 1 0 062 104 090 1 640 0 050 10 00 0 010 zc 3 17670 6 0 062 150 139 0 987 0 050 10 00 0 220 2 za 6 59040 10 0 095 57 532 1680 0 050 10 00 0 360 Figure 5 23 Spray zone properties for full caster simulation 54 La T E H 0 250 870 250 0 05 0 50 0 95 0 60 150 0 60 Figure 5 23 cont Spray zone properties for full caster simulation 5 3 6 Outputs After reading in the outputs as explained earlier in secti
23. 50 0 95 0 60 1 50 0 60 4 2828 0 5 0 070 60 182 1 008 0 050 10 00 0 200 0 250 8 70 25 0 0 10 0 50 0 90 0 50 3 36 0 50 5 3774 0 10 0 080 60 182 1 620 0 050 10 00 0 360 0 250 8 70 25 0 0 40 0 50 0 80 0 40 4 11 0 40 6 5904 0 10 0 095 57 532 1 680 0 050 10 00 0 360 0 250 8 70 25 0 0 12 0 50 0 80 0 02 0 92 0 02 7 8260 0 12 0 095 35 000 1 680 0 050 10 00 0 360 0 250 8 70 25 0 0 20 0 50 0 70 0 02 1 00 0 02 11246 0 End of last spray zone mm 0 Consider Leidenfrost effect 1 yes 0 no0 5 Number of points in the Leidenfrost effect curve if above 1 Next 2 lines contain Leidenfrost effect h multipliers and temperatures 1 0 2 5 1 8 1 3 1 500 600 700 800 900 MOLD COOLING WATER PARAMETERS 43 00000 Cooling water temperature at mold top C 0 6200000 Cooling water pressure MPa 1 Form of cooling water velocity flowrate 1 m s 2 L s 8 500000 8 500000 Cooling water velocity flowrate per face WF NF gt 0 cooling water from mold top to bottom lt 0 cooling water from mold bottom to top 2 Parameters to update every heat SLAB GEOMETRY 90 00000 Slab thickness mm 1396 000 Slab width mm 950 0000 Total mold length mm 35 00000 WF Mold thickness with water channel mm outer rad top 35 00000 WF Mold thickness with water channel mm inner rad top STEEL PROPERTIES 0 0600 1 1500 0 0020 0 0100 0 1880 C Mn S P Si 0 0400 0 0400 0 1200 0 0100 0 0020 Cr Ni Cu Mo Ti 0 0200 0 0010 0 0080 0 0350 0 0000 AI V N Nb
24. I I I I I I I I I I r I I I I I I I I I I I I I r I I I I I I I I I I I I I F I I I I I I I I I I I I I F I I I I I I I I I I I I I F I I I I I I I I I I I I I 3 0E 06 e QQ HH bien 1 i ft e m e m a e m m ee m m h a a e e e m e m e e e e d a e m m e m e e m m e m m d a e e e e m e m e e e m dl a e e e e e e m m e e m e d e e m m e e e e e e e m l a e e m e e m m m m e Le Ed 559115 Je9YS EP eae e n a ee ___ _ f 5 0E 05 Distance Below Meniscus mm Shear Stress on Mold Wall n a 0 Node9 0 Max up Mode 1 2 8 vmokd 3 8 Node 13 4 8 max dn Mode17 Ed 559115 Jeayg i 0 Max up i Pa Figure C 23a Shear stresses in gap out shr for the mold simulation Distance Below Meniscus mm Max Down Stroke Max Up adist Up Axial Un Axial Stroke 99 Shear Stress at Flux Layer Solid Liquid Interface 1 0E 05 8 0E 04 6 0E 04 4 0E 04 2 0E 04 0 0E 00 Shear Stress Pa 2 0E 04 4 0E 04 300 400 500 600 700 Distance Below Meniscus mm Figure C 23b Shear stresses in gap out shr for the mold simulation 100 L er di nm k di Ji HUA MAI np UO pewag 4 64 F4 JOH 2 U 11906 Temperature C Figure C 24a Steel prope
25. I I I I I I T I I I I I I I I I I I I I I I 4 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I 3 5 I w a m m m a m m m m m m a m d n a m m m a m a m n m m m m m Ln m m m m e m m m m a m m m m H T T T E moa a ee E vU AAN XN IS 4e3H Distance Below Meniscus mm Hotface HE Coldface h 4 J 10000 MZ y LU 1091910907 JAJSUPI JRO Distance Below Meniscus mm hwater H hmold Figure C 17b Mold data out mld for the mold simulation 89 E E g E _ a ke a deg ES a i a a a G o o 200 400 600 800 1000 Distance Below Meniscus mm Figure C 17c Mold thickness data out mld for the mold simulation 90 EndWall Deflection mm 200 400 600 300 Distance Below Meniscus mm I I I I T I I I I T I I I I T E End Watll Defl 25 Mold Ostr 8 Extra Length Ideal Tpr Def EndWall Deflection mm 4 __ lt lt 200 400 600 Distance Below Meniscus mm Miti End VVatll End VVatll tr B eal Ideal Tpr Position Defl 1s WF Expn NF Dstr Mold D t Cumul Figure C 18a Taper histories out tpr for the mold simulation 91 on EndWall Deflection mm cn S S 40
26. More help to explain the theory behind the program could be added as comments to explain how each input variable is used More error checking could be added to detect unreasonable values of important parameters such as caused by typographical errors or units problems Finally CONID itself is continuously changing to incorporate new features The interface will need to change with CONID to be functional in the future 59 10 11 12 13 REFERENCES Dix A J and J E Finlay Human Computer Interaction Sted Prentice Hall 2007 Godet Bar G D Rieu and S Dupuy Chessa HCI and Business Practices in a Collaborative Method for Augmented Reality Systems Information and Software Technology 32 5 2010 492 505 Ho Bryant Characterization of Interfacial Heat Transfer in the Continuous Slab Casting Process MS Thesis University of Illinois 1992 Langeneckert Melody Influence of Mold Geometry on Heat Transfer Thermocouple and Mold Temperatures in the Continuous Casting of Steel Slabs MS Thesis University of Illinois 2001 Lewis Clayton and John Rieman Task centered User Interface Design a Practical Introduction Boulder Colo University of Colorado Boulder Dept of Computer Science 1993 Hibbeler Lance Thermo Mechanical Behavior During Steel Continuous Casting in Funnel Molds Thesis University of Illinois 2009 Meng Ya Modeling Interfacial Slag Layer Phenomena in the Shell Mo
27. P Dstaut enter value 700 PTS Steel Thermal Conductivity M Default Enter Value Steel Thermal expansion Coeff Enter Value 1 30 Figure 5 18 Steel slab properties for full caster simulation Mold Properties Mold Cooling Water Parameters Cooling water temperature at mold top Cooling water pressure Cooling water velocity or flowrate Cooling water 8 500 8 500 Y Cooling water from mod top to bottom Cooling water from mod bottom to top Mold Water Properties Heat transfer coefficient M Default Enter Value a METTA Water heat capacity IZ Default Enter Value MA JAR kg m3 Water density M Default Enter Value Figure 5 19 Mold properties for full caster simulation 50 Mold Geometry Funnel depth at mold top mm Machine outer radius Machine inner radius Narrow face NF mold thickness with water channel Mean temperature diff between hot amp cold face of NF NE 20 000 22 000 Total channel cross sectional area 8300 00 400 00 LS Channel distance center to center 6300 00 400 00 Mold thermal conductivity 350 000 350 000 WAC Mold thermal expansion coeff 1 60E 05 Figure 5 19 cont Mold properties for full caster simulation 5 3 4 Thermocouples This simulation uses 45 thermocouples in the mold The offset for this simulation was not known as a finite element analysis of the mold including the thermocouple geometry was not conducted Thus this option
28. W 0 0000 Co additional components 1000 Grade flag 1000 304 316 317 347 410 419 420 430 999 1 If CK simple Seg Model wanted for default Tliq Tsol 1 yes 0 no 10 00000 Cooling rate used in Seg Model if above 1 K sec Override defaults with following constants 1 default 1 000000 Steel liquidus temperature C 1 000000 Steel solidus temperature C 1 000000 Steel density g cm 3 1 000000 Heat fusion of steel kJ kg 1 000000 Steel emissivity 1 000000 Steel specific heat kJ kg deg K 1 000000 Steel thermal conductivity W mK 1 000000 Steel thermal expansion coeff K 3 Parameters to update when model is calibrated ISIMULATION PARAMETERS 849 0000 Z distance for heat balance mm 0 Which shell to consider O wide face 1 narrow face O What type of mold 0 slab 1 funnel 2 billet 1 shell only 2 Which moldface to consider O outer 1 inner 2 straight 1 000000 Is superheat treated as heatflux O no 1 yes take default 1 yes enter data 17 Number of zmm and q data points if above 1 Next 2 lines contain zmm mm and q kW m2 data 10 45 100 200 300 400 500 675 720 770 980 1120 1370 1470 1575 1700 2000 20 40 58 57 28 36 88 384 408 406 321 303 98 58 38 25 20 62 1 Do you want more accurate 2d calculations in mold 0 no 1 yes 2 yes one extra loop for better taper 850 0000 Max dist below meniscus for 2d mold calcs mm mold length if above 2 3 0000
29. e e a e r a r e e e d a e ee a m r e e e e a e a e L a a a e a a n m r r r a r a m r e e a dl a a n m e a e a r a a n e r e m a a a e L an e a e a a n e r n e ee e aE 4 SET AH o a LO o LO N e 9 aunjesa duo L 9 almesadwa gudana nase PER La ae ct x e e m eee eee eee eee ee e e e B E a a S e e bite Distance Below Meniscus mm 4 Mold Temp cold Ak Tsurf Mold Temp hot Mold Temp hotcu Figure 5 12 Graph of mold temperature output from mold simulation example 45 The mold flux gap page gpt file displays information related to heat transfer coefficient flux layer thicknesses and flux viscosity down the mold The graph of the thickness of the solid and liquid mold flux layers down the mold are shown in Figure 5 13 _ dsolid A 2 aoe ers oe AB dliquid E wi E ox k a a re mua gt LL ae a a es eccone 4 k 4 A PA AO PA eases o recnalreranceneboncemncaponconnsarponnceeontboreno 400 500 600 700 800 Distance Below Meniscus mm Figure 5 13 Flux thickness graph output of the mold simulation example The flux temperature page fxt file gives the temperature of the mold flux down the mold Figure 5 14 shows the flux temperature graph of this mold simulation
30. little load on the user s memory to use this interface Taking the example of the inner and outer spray zones many simulations want to input the same spray zone flow rates on both the inner and outer radius To make this easy a button is present to copy the information from the inner radius to the outer radius so the user does not have to manually copy the data between worksheets When outputs are read in the file name run titles time and date of the reading are shown on each output page This ensures that the user knows which run outputs are being examined and when the output was last updated The same color scheme and button layout is used throughout the entire interface to achieve the benefits from consistency For example all white cells are for data entry all green cells are for parameter description and light blue cells are to present output data Italics convey automatically generated input data and gray cells contain inactive input data that will not be used in the simulation Much of the interface demonstrates feedback in one form or another Changing the unit set changes all the unit labels throughout the interface so the user always knows which unit 1s needed for a given cell Running a final data check provides feedback by showing the user 1f information needs to be entered and where Reading in outputs changes the worksheet to the 26 output worksheet while updating the data to let the user see that data 1s being read in Such
31. one spray zone Each column after the casting speed 1s designated to a specific pattern For each pattern and each casting speed a water flow rate needs to be entered for the spray zone The znames column that is second from right includes the zone name and must be copied over for each row of casting speeds in that zone The last column of data includes the number of rows in the zone and must be copied over for each row of casting speeds in the zone When the casting speed or spray pattern 19 changed the macro will interpolate between the casting speeds on the spray table to find the water flow rate for each spray zone and divide by the number of rows to get the flow rate per row Then the macro will match the spray zone name in the spray table worksheet to the spray zone name in the spray zone input worksheet update the water flow rate and change the font to italics to indicate each number that was automatically generated The spray table also features water flow rate graphs for each spray zone The graphs give a visually appealing way to 19 view the tabular flow rate against the casting speed data It is also very easy to spot mis entered or non consistent values in the spray table When the spray table is initially created or edited the CLICK 1f spray table has been updated button must be clicked This button will re graph the spray table flow rate graphs reset the pattern drop down menu and update spray zone information 1f wanted
32. ors e formato File Parti Ci My Dore YAP College L rep h Proce Uaa 1008 1 00 HD ATR me fonu roan cament ecommerce rn Kaha me contanti Kr ata A a Metals Processing Simulation Lad Changing Security Settings Office 2007 n orti 09 ee mpe te 20 ort mon v pra fu oe Ms i Pi MR 9 Pr pa Lr Univecssty of Ilisois at Urbena Champarzo 68 Was millors Tai minal Mm CELIA e a Verde e AAA ee KR aspi mr naviga 4 Z Iw 04 marini oom API P Durbe of meim YR o gt rr s misto tro qnet poet agri ter CA A rp ra rr pr Ue e van txa grt TO The xa jan maT ce Metals Processing Simulation Lab APPENDIX C INPUTS AND OUTPUTS FOR A MOLD SIMULATION Enter Casting Speed 1 00 TY FH Update spray zones Varying Casting Speed from spray table Pour Temperature 1550 000 Ham Distance of Meniscus from top of mold 94 000 Nozzle submergence depth Max Simulation length 1500 00 How to calculate shell mold PAPA interface heat transfer CONTO will calculate interface heat kased on meld Au CCE HERE to enter heat Aue cata ana mala Aus properties bath sections Figure C 1 Casting condition parameters for mold simulation Shell face to consider Mold type Mold face to consider 2D calculation give more accurac Max Distance below meniscus for 2D calculation Shell thermocouple number below hot face Is superheat treated as he
33. page of data on the properties of the gap materials and other parameters that control heat transfer across the interface between the shell and the mold This example uses flux casting as the method to calculate the heat transfer in the mold The simulation parameters contain parameters related to the computational modeling and not of interest to casting engineers unfamiliar with CON1D These include choice of 2D mold calculation time step size max simulation thickness superheat treatment and many others The entered simulation parameters for the mold example are shown in Figure 5 3 The 2D calculation in the mold parameters can only be used if the shell mold interface heat transfer was set to either 34 oil casting or flux casting This parameter allows for a 2D mold calculation from the meniscus to any specified distance down the mold in order to gain extra accuracy by accounting for axial heat conduction The remainder of the mold uses a 1D calculation to save computation This simulation chooses a 2D calculation from the meniscus to 800mm below the meniscus which is the entire mold length The max simulation thickness is generally set to the same value as the slab thickness on the steel slab properties page Choosing the default option for this parameter will automatically make sure that max simulation thickness is set to the same value as the slab thickness Both of these values are set to 230 10mm for this simulation
34. properties are set as shown in Figure 5 4 This worksheet is split into the slab geometry and steel properties sections The slab geometry includes the slab thickness width total mold length and mold thickness with water channel As stated earlier the slab thickness generally 1s the same value as the max simulation thickness Thus changing the slab thickness prompts the user about changing the max simulation thickness to match This example simulates a steel slab 230 1 mm thick and 1500mm wide The mold length is set to 894mm The steel properties section includes variables such as the steel alloying element composition and the thermal properties To assist users a preset grade table is available to store commonly cast grades as explained in Chapter 3 Once the grade table is setup a user can use the drop down menu to choose the wanted preset grade The first choice is a manual grade where the user can enter the data manually into the boxes If a preset grade is chosen the data will be overwritten with the stored data in the grade table worksheet A user can choose a preset grade and change select values if wanted The grade flag parameter should be set to 1000 unless an 36 advanced user with knowledge of the grade flag chooses otherwise This example sets a manual steel composition with a grade flag of 1000 CONID also incorporates a segregation model if requested in order to compute the liquidus and solidus temperatures and t
35. represent inner and outer radius rather than left and right side Many inexperienced users of CONID do not understand the parameters that need to be entered in To account for this most parameters have descriptions or comments to help users understand The z1 z2 z3 hl h2 and h3 parameters in the spray zones worksheets did not have a description for inexperienced users to understand To resolve this problem a picture describing the meaning of the parameters was added One user found that when writing the input file the interface would overwrite an already existing input file with a matching name in the same working directory Additionally there was no warning to the user that existing input files could be overwritten automatically To solve this problem a message box prompts the user with a yes and no option when the name of the input file to be written overwritten matches an existing file in the same working directory 29 CHAPTER 5 USER MANUAL WITH EXAMPLE PROBLEMS 5 1 Overview This chapter presents the user interface by first introducing the setup homepage writing of the input file and running the program and reading of output files for post processing Then two example simulations are presented to illustrate how the user interface works in detail The first example demonstrates a mold simulation and focuses attention on the inputs related to the mold and interface pages The second example explains a full caster simul
36. speed of the model prompted a derivative simulation CONONLINE which is being used as the core of an in plant spray zone control system CONONLINE is modified to run simulations faster and restart simulations from pervious data to move slices as they travel down the mold CHAPTER 2 BACKGROUND 2 1 Project Goals The goal of this project was to create a user friendly interface to improve the usability of the CONID The new interface required the following ability to change input parameters and write the input file run CONID and to present the output in familiar graphical form The form of the input and output should be easily modified by the users according to their individual needs and desires The program CONID is updated frequently to incorporate new features As the input and output files change for CONID so must the interface The interface needs to be flexible to change in the future to incorporate the changes of CONID 2 2 Pervious Interface The previous program used a text based interface to create the input file an interactive DOS window to run the CONID program and scripts for Gnuplot for post processing 2 2 1 Input File The input file for CONID is a text file that ranges in size but 1s approximately 300 lines in length The input file 1s split into 11 major sections Casting Condition Spray Zone Variables Mold Cooling Water Parameters Slab Geometry Steel Properties Simulation Parameters Mold Flux Properties Interface Heat
37. than horizontally For example Figure 3 9 shows the special menu to set up the units for the flux powder consumption rate Special menu for flux al ti to Con Mass per area or powder consumption rate er welght Metric per Area oma Aree British per Area s t Metric per Weight kg tonn Vea British per Weight lbs ton S ht Figure 3 9 Layout of the units menu for special items such flux powder consumption rate COND can handle either kg m or kg tonne for the units of this parameter To allow for the English equivalent of either of these choices lbs ft and Ibs ton were also added If the user chooses to use the custom set of units they must choose either Mass per Area or Mass per Weight in the Mass per area or per weight column This will give the appropriate information to the Interface to convert the chosen units to either kg of powder consumed per m of steel strand surface if Area is chosen or kg of powder consumed per tonne of steel cast if Weight 1s set Then the users must enter a label to convey their units for the appropriate consumption rate to replace the place holder label Custom in the cell to the right of Custom per Area Weight They then must enter the conversion factor from their units into the CON1D units of kg m if 23 Area is chosen or into kg tonne 1f Weight is chosen The special menu for the cooling water works in a similar way except with velocity and fl
38. with some knowledge of the theory behind the models used in CONID These new users do not necessarily know the usage of parameters depending on the choices made for the simulation Both sets of researchers generally use this software to simulate casting processes of specific casters as accurately as possible The researchers are generally the users that will calibrate many of the input parameters to the specific caster Another group of users is the casting operators Most of these users do not understand the details of the theory behind the computational modeling software The casting operators typically do not setup all of the input parameters needed to calibrate CONID but rather rely on some input parameters already calibrated from previous work to run simulations Casting operators are familiar with casting condition parameters such as casting speed spray pattern or steel grade but are not familiar with the specific variables units and format required by CONID The casting operators are usually not skilled in using command line based graphical software such as required for Gnuplot With the new interface developed in this project it is expected that the use of CONID can be expanded from the current user base to new researchers and caster operators With an easy to understand interface casting operators and non experienced researchers can then use CONID as easily as experienced researchers 2 4 Platform The new interface uses Microsoft Ex
39. 0 000 43 2 tl 439 Figure D 13a Mold data out mld for full caster simulation 43 2 43 2 100 0 150 00 140 123 I I I I I I I I I I I I I I I I I ae I I I I I I I I I I I I I I I I I T I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I _ r cirie E i Oer N a oops 1 Gai E C y ULZ W AAWI Xn pat Distance Below Meniscus mm t Hotface A8 Coldface 40000 _ 4 hk 4 h 4 DS A sl A sl 1000 1000 21 HZ VU A Jud roya 02 JajSULIL JeaH Distance Below Meniscus mm hwater HF hmold Figure D 13b Mold data out mld for full caster simulation 124 E E E E _ BD a Tm et a a Oo e 200 400 600 s00 Distance Below Meniscus mm Figure D 13c Mold data out mld for full caster simulation 125 fr EndWall Deflection mm e A eee eet a 400 600 800 Distance Below Meniscus mm A End Watll Defl 25 Mold Dstr Extra Length t_ldeal Tpr Def E pr E a E G E LU 400 Bl 1000 Distance Below Meniscus mm Figure D 14a Taper histories out tpr for full caster simulation 126 A8 End Watll Defl 2s NF Expn
40. 0 1000 1200 1400 1600 Temperature Figure 5 11 Mold flux parameters for the mold simulation 43 Liquid Flux Conductivity Kiquid Number of data points Tkliquid ARES Tkliquid 0 4 0 5 0 6 ICA EA Z distance below meniscus Solid flux velocity to casting speed 0 3 0 4 05 0 6 Z distance below meniscus Number of data points Friction Coef 0 400 0 3 04 0 5 0 6 Z distance below meniscus Figure 5 11 cont Mold flux parameters for the mold simulation 44 5 2 6 Outputs After reading in the calculated results from the output files as explained earlier in section 5 1 4 the mold simulation outputs such as the mold temperatures flux powder thicknesses and flux temperatures can be examined The mold mld page includes data such as mold temperatures and heat flux profile down the mold The graphs from the mold page read from the mld file where is the identifying name of the simulation are shown in Figure 5 12 I I I I I I I I I I r I I I I I I I I I I L I I I I I I I I I I I r I I I I I I I I I I E I I I I I I I I I I I I I I I I I I I I 4 k 4 LIRE SEO CO SOSIO COMO e cei eee ese ce m m m m m dh TT a m mme PU T oono Distance Below Meniscus mm id Mold Temp hot Mold Temp hotcu Mold Temp cold a e e m a r a m r
41. 0 600 500 Distance Below Meniscus mm E bea Er a FP E 400 600 800 Distance Below Meniscus mm Figure C 18b Taper histories out tpr for the mold simulation 92 Output Heat Transfer History in Spray Zones below Mold _ hnconw hrad A hspray hconv2 htot La lt E ei amp G oO S w E E La H der E a 600 800 1000 Distance Below Meniscus mm ad 9 nv2 htot 810 0 Be 1417 00 000 150 44 820 0 87 1479 oof 000 156 63 830 0 8 7 1525 00 000 16124 840 0 87 1563 00 000 165 02 850 0 87 1596 00 000 16826 860 0 87 1624 oof 000 17111 Figure C 19 Spray zone heat transfer out spr for the mold simulation 93 Output Powder Layer Consumption and Velocities 2 E 06 2 E 06 3 0E 03 Velocity m s 1 E 06 2 0E 03 Powder Consumption m 2 s 0 0E 00 0 100 200 300 400 500 600 700 500 900 Distance Below Meniscus mm gconsumpt E gosciltn A gliquid qsolid vliquid 8 vsolid b r E mi T l ra sul L te sli L Qui gsold guig vsolid _ 1 250E 06 2 200 2 740E 06 1 2506 06 1 190E 06 3 040E 07 52606 03 1000E 03 en n A FAME ME d ALEM ME 4 ASE ME F EME AT E S AE ma d Nn ma Figure C 20 Powder layer consumption and velocities out gpv for the mold simulation C L IST JE LI iui e eee i i 4 dsolid ife 4 k
42. 0 FO 3068 530 FO 5903 250 FO 6130 250 FO 8260 095 19 700 L 10 00 2250 FO 10 8495 095 19 700 l2 10 00 250 FO 11 10995 8 115 19 700 la 10 00 250 FO 11246 0 End of last spray zone mm 0 consider Leidenfrost effect 1 yes 0 n0 5 Number of points in the Leidenfrost effect curve Cif above 1 Next 2 lines contain Lejdenfrost effect h multipliers and temperatures Lib 2 5 1 8 1 3 1 500 600 700 500 900 F J bJ Po FJ Lil CT mT nP owd Ln Deg 9 900 O 050 16 00 050 10 00 050 10 00 LAO 10 00 176 10 00 176 10 00 204 10 00 204 10 00 cm 0 062 062 172 300 062 107 800 070 31 200 080 11 000 080 11 000 095 15 200 095 15 200 D10 080 2220 200 350 350 350 350 350 350 3650 1 El 3 4 5 6 7 D E I C3 L G Gn Gn J C C3 C3 LA PopPwoFoPuouk C3 C3 C3 C3 C3 C3 C C3 C3 C3 G GGG LG G L O C3 C3 C3 C3 C3 C3 C C3 C C3 C3 C3 C3 C3 C3 C3 C C3 C3 o C C3 C3 C3 C3 C C3 C C3 C C3 CO GD 00 00 00 gd GO GD G GD C3 C3 C C C C C C C3 C3 C3 C3 C3 C3 a C3 C3 KC K C3 C3 C3 O C3 C3 C3 C3 C C3 C C3 C C3 C C3 C3 C3 C3 C C3 C C3 C C3 Figure 2 1 Using Notepad to edit input file data Data is not visually appealing 2 2 2 Running CONID The program CONID is complied in FORTRAN and is run as an executable file The executable file opens up a command prompt and asks the user to type in the name of the input file that he would like to run Then
43. 00 ___ _ I I I I I I I I I I I I I I I I I I I I I I I I i I I I I I I I I I I I I I I I I I I I I I I I I i I I I I I I I I I I Sotbooooooocooobooooooooo e pon i x uogeguazuon _ r r r 1495 eg ES I I dm da k d Pi pe ee ee t A 0 4 Time sec d e 9 ainjejodua 1510 1505 w m m m m d e m m m e e m m e e m m m m m e m v m l n m m m m m m m m m d n m m m m m e e m m dl a w m m m m m m m m la a m m m a a m m m m I L I I I I I I v m m m m m m m m e d n m m m m m m m m m sl a m e e m e m m m m la a m m m m m m m m L n a m m m m m m m m l a e m m m m m m m m ln a m m m m m m m K L L L RE o 0 a x WONeIUaIU J Distance Below Meniscus mm Temp Mc Figure D 19 Liquid phase concentrations 10 00mm below surface out lq1 for full caster simulation 135 Temperature C Concentration 550 910 940 1000 1030 1060 Distance Below Meniscus mm o L E E L a E a eni Concentration 0 770 1 Figure D 20 Solid phase concentrations 10 00mm below surface out sli for full caster simulation 136
44. 0000 Nozzle submergence depth mm 0 New simulation or Restart 0 new 1 restart 15000 00 Max simulation length must gt z distance mm 1 Calculate mold and interface 0 flux casting or 2 oil casting or enter interface heat flux data 1 or avg mold flux 2 or cooling water temp increase 3 8 Number of zmm and q data points if above 1 Next 2 lines contain zmm mm and q kW m2 data 0 00 100 00 200 00 300 00 410 00 550 00 850 00 950 00 5360 00 3410 00 2600 00 2350 00 2340 00 2310 00 970 00 500 00 2 4243 2 4243 Average mold heat flux MW m 2 if above 2 9 8800 9 8800 Mold cooling water temp increase Deg C 1f above 3 1 Running mode 0 stop right now 1 continue to run positive integer ts run the program for ts seconds SPRAY ZONE VARIABLES 8 700000 Minimum convection heat trans coeff natural W m 2 K right side 25 00000 Water and ambient temperature after spray zone Deg C spray zone condition heat tran coeff funct h A C W n 1 bT Nozaki Model A C 0 3925 n 0 55 b 0 0075 1 570000 A 0 off 0 5500000 n 7 4999998E 03 b 7 Number of zones No zone rol water spray contct frac of spray cony amb starts rad flowrate width length angle q thr rol coeff coeff temp zl z2 z3 hl h2 h3 mm m I min row m m Deg W m 2K DegC 1 850 0 1 0 062 104 09 1 640 0 050 10 00 0 010 0 250 8 70 25 0 0 08 0 50 0 92 0 30 1 00 0 30 2 940 0 5 0 062 239 970 0 987 0 050 10 00 0 080 0 250 8 70 25 0 0 0
45. 0000002E 03 Slag rim thickness at metal level meniscus mm 9 9999998E 03 Slag rim thickness at heat flux peak mm 5 000000 Liquid pool depth mm 80 00000 Solid flux tensile fracture strength KPa 8000 000 Solid flux compress fracture strength KPa 0 1700000 Solid flux Poisson ratio 1 number of slag static friction coeff data Next 2 lines contain zmm and Static friction coeff 0 0 500 0 5000000 Moving friction coefficient between solid flux and mold wall INTERFACE HEAT TRANSFER VARIABLES 13 Number of distance vratio data points 1 constant ratio of solid flux velocity to casting speed Next 2 lines contain zmm mm and ratio data O 10 60 100 190 300 400 410 450 600 800 1000 1096 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 200 0 100 0 200 0 0000000E 00 Flux mold or shell mold contact resistance m 2K W 0 5000000 Mold surface emissivity 5 0000001E 02 Air conductivity in oscillation marks W mK O Osc marks simulation flag 0 average l transient 0 0000000E 00 Oscillation mark depth mm 1 000000 Width of oscillation mark mm 3 750000 Oscillation frequency cps 1 take default cpm 2 ipm casting speed 9 000000 Oscillation stroke mm 63 MOLD WATER PROPERTIES 1 000000 heat transfer coefficient W m 2K 1 default f T based on Sleicher and Rouse Eqn 1 000000 Water heat capacity J kgK 1 default f T 1 000000 Water density kg m3 1 default f T MOLD GEOMETRY 36 00000 Narrow face
46. 000E 03 Time increment s 180 Number of slab sections 10 00000 Printout interval mm 0 0000000E 00 Start output at mm 90 00000 Max simulation thickness mm smaller of max expected shell thickness amp slab thickness 200000 Max number of iterations 3 Shell thermocouple numbers below hot face less than 10 Next line gives the distance below surface of thermocouples mm 10 0 125 25 0 0 7000000 Fraction solid for shell thicknesss location 0 Do you want to print all the files for the related information for each slice 0 no 1 yes remark choosing 1 would slow down the program MOLD FLUX PROPERTIES 35 40 26 60 3 60 8 80 0 50 Ca0 S102 Mg0 Na20 K20 0 00 0 20 0 00 0 50 0 00 FeO Fe203 NiO 7MnO Cr203 3 50 0 00 0 00 0 00 0 00 ARL03 T102 B203 L120 Sr0 0 00 10 20 5 30 8 00 8 20 Zr02 F free C total C CO2 1 number of Tfsol and viscosity exponent n Next 3 lines contain zmm mm and tfol and expn data 0 1180 00 2 000 0 8000000 Solid flux conductivity W mK 1 number of Liquid flux conductivity data Next 2 lines contain zmm and Tkliquid data 0 1 400 0 2500000 Flux viscosity at 1300C poise 2700 000 Mold flux density kg m 3 200 0000 Flux absorption coefficient 1 m 1 000000 Flux index of refraction 1 take default f composition 0 9000000 Slag emissivity 1 Form of mold powder consumption rate 1 kg m 2 2 kg t 0 1500000 Mold powder consumption rate 0 0000000E 00 Location of peak heat flux m 4
47. 03 b 4 Number of zones No zone rol water spray contct frac of spray conv amb starts rad flowrate width length angle q thr rol coeff coeff temp zl Z2 z3 mm m I min row m m Deg W m 2K DegC TI hl 1 00 1 00 1 00 1 00 hl h2 1 00 1 00 1 00 1 00 h2 h3 1 00 1 00 1 00 1 00 h3 800 0 2000 0 2710 0 8700 0 14000 0 0 5 BR WN OL i i 1 0 500 0 075 18 882 0 984 0 904 0 00 0 010 0 250 8 70 25 0 0 00 0 075 9 187 0 984 0 050 10 00 0 080 0 250 8 70 25 0 0 00 0 095 5 195 0 984 0 050 10 00 0 220 0 250 8 70 25 0 0 00 0 095 3 897 0 984 0 050 10 00 0 200 0 250 8 70 25 0 0 00 End of last spray zone mm Consider Leidenfrost effect l yes 0 no Number of points in the Leidenfrost effect curve if above 1 Next 2 lines contain Leidenfrost effect h multipliers and temperatures 2 5 1 8 1 3 1 0 600 700 800 900 MOLD COOLING WATER PARAMETERS 30 000 0 202 1 7 800 Cooling water temperature at mold top C Cooling water pressure MPa Form of cooling water velocity flowrate 1 m s 2 L s 7 800 Cooling water velocity flowrate per face WF NF gt 0 cooling water from mold top to bottom lt 0 cooling water from mold bottom to top 2 Parameters to update every heat SLAB GEOMETRY 230 100 Slab thickness mm 1500 000 Slab width mm 894 000 Total mold length mm 51 000 WE Mold thickness with water channel mm outer rad top 51 000 WE Mold thickness with water channel mm
48. 10 80 200 00 21 10 80 250 00 22 10 80 300 00 23 10 80 400 00 24 10 80 500 00 25 10 80 600 00 26 10 80 700 00 27 10 80 790 00 28 15 80 0 00 29 15 80 20 00 30 15 80 30 00 31 15 80 50 00 32 15 80 70 00 33 15 80 85 00 34 15 80 100 00 35 15 80 120 00 36 15 80 140 00 64 15 80 15 80 15 80 15 80 15 80 15 80 15 80 15 80 15 80 170 00 200 00 250 00 300 00 400 00 500 00 600 00 700 00 790 00 65 APPENDIX B INTERFACE INSTALLATION NOTES Directory Help Notes Start with CON1D9 7 1 exe in the same folder as the excel interface It is best to have CON1D9 7 1 exe the excel interface input files and output files all in the same folder The excel interface will write the input files into the working directory which is the directory the excel interface file Is located The outputs will be written into this directory by CON1D and then can be read into the interface for viewing The input and output files need to be in the same folder as the excel interface file to read in and graph the output data University of limos at Urbana Champejen a Metals Processing Simulation Lab 66 la Cie Starting the Interface Satira a oras ce Laren You may need to enable macros upon startup of the xls file Usually this IS solved by answering Enable Macros to prompting lf you have macros disabled you may have to change security settings Starting the interface and enabling macros Is described with p
49. 1000 00 1118 00 70 00 720 00 250 00 125 00 100 00 Do you want more accurate 2d calculations in mold 0 no 1 yes 2 yes one extra loop for better taper Max dist below meniscus for 2d mold calcs mm mold length if above 2 Time increment s Number of slab sections 78 0 50 0 50 0 50 0 50 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 00 1 0 0 0 060 10 000 Printout interval mm 0 00E 00 Start output at mm 230 100 Max simulation thickness mm Usually the slab thickness 1000000 Max number of iterations 3 Shell thermocouple numbers below hot face less than 10 Next line gives the distance below surface of thermocouples mm 10 0 12 5 25 0 0 300 Fraction solid for shell thicknesss location 0 Do you want to print all the files for the related information for each slice 0 no 1 yes remark choosing 1 would slow down the program MOLD FLUX PROPERTIES 32 30 36 40 0 70 5 00 1 90 CaO S102 MgO Na20 K20 3 00 0 00 0 00 0 00 0 00 FeO Fe203 NiO MnO Cr203 8 90 0 00 3 40 0 00 0 00 A1203 T102 B203 Li20 SrO 0 00 8 30 0 00 0 00 0 00 Zr02 F free C total C CO2 1 number of Tfsol and viscosity exponent n Next 3 lines contain zmm mm and tfol and expn data 0 0 950 00 1 600 1 500 Solid flux conductivity W mK 1 number of Liquid flux conductivity data Next 2 lines contain zmm and Tkliquid data 0 0 1 500 4 300 Flux viscosity at 1300
50. 15 80 60000 8358 ao 580 Tooo TATA gt _ Figure D 8c Calculated exit conditions and thermocouple data out ext for full caster simulation Lad Lad Cal j oo a 117 Shell Thickness Entire Run 2000 4000 6000 8000 10000 12000 14000 16000 Distance into Shell mm Shell Thickness mm 2000 4000 6000 8000 10000 12000 14000 16000 Distance into Shell mm Figure D 9a Shell thickness and temperature out shl for full caster simulation 118 I I 1 I I 1 I 1 I I 1 I j I 1 I I I 1 I I 1 I I 1 I J 1 I I I 1 1 I 1 I 1 I 1 I 1 E 1 I I 1 I I I 1 I 1 I 1 i I I 1 I I 1 I I I I 1 I I J 1 I 1 I I 1 I I I 1 I I 1 I a 1 I I I 1 I I 1 I I 1 1 I I El i e e S cosobossnor beoseecocoosaos A A el a a e n n e n m e A A A A e n ed a e a a a e a e e a ee o anger ciu L 11945 Distance into Shell mm Figure D 9b Shell thickness and temperature out shl for full caster simulation prime RAS Ts on 5 E an un C E an on De Ll K un on De i Li Fositon Figure D 9c Shell thickness and temperature out shl for full caster simulation 119 A v e e e e e e AA ol 4 Temperature mold exit a Temperature 4 balance I Ae E a e e e m e Temperature C 15 20 Distance into Shell mm Super Heat mold exit a Sensible Heat mold
51. 2 0 50 0 98 0 50 2 20 0 50 3 1767 0 6 0 062 150 139 0 987 0 050 10 00 0 220 0 250 8 70 25 0 0 05 0 50 0 95 0 60 1 50 0 60 4 2828 0 5 0 070 60 182 1 008 0 050 10 00 0 200 0 250 8 70 25 0 0 10 0 50 0 90 0 50 3 36 0 50 5 3774 0 10 0 080 60 182 1 620 0 050 10 00 0 360 0 250 8 70 25 0 0 40 0 50 0 80 0 40 4 11 0 40 6 5904 0 10 0 095 57 532 1 680 0 050 10 00 0 360 0 250 8 70 25 0 0 12 0 50 0 80 0 02 0 92 0 02 7 8260 0 12 0 095 35 000 1 680 0 050 10 00 0 360 0 250 8 70 25 0 0 20 0 50 0 70 0 02 1 00 0 02 11246 0 End of last spray zone mm O Consider Leidenfrost effect l yes 0 no 5 Number of points in the Leidenfrost effect curve if above 1 Next 2 lines contain Leidenfrost effect h multipliers and temperatures 1 0 2 5 1 8 1 3 1 500 600 700 800 900 left side 25 00000 Water and ambient temperature after spray zone Deg C spray zone condition heat tran coeff funct h A C Wn 1 bT Nozaki Model A C 0 3925 n 0 55 b 0 0075 1 570000 A 0 off 61 0 5500000 n 7 4999998E 03 b 7 Number of zones No zone rol water spray contct frac of spray conv amb starts rad flowrate width length angle q thr rol coeff coeff temp zl z2 z3 hl h2 h3 mm m I min row m m Deg W m 2K DegC 1 850 0 1 0 062 104 09 1 640 0 050 10 00 0 010 0 250 8 70 25 0 0 08 0 50 0 92 0 30 1 00 0 30 2 940 0 5 0 062 239 970 0 987 0 050 10 00 0 080 0 250 8 70 25 0 0 02 0 50 0 98 0 50 2 20 0 50 3 1767 0 6 0 062 150 139 0 987 0 050 10 00 0 220 0 250 8 70 25 0 0 05 0
52. 79 000 Water heat capacity J kgK 1 default f T 995 600 Water density kg m3 1 default f T 79 MOLD GEOMETRY 51 000 30 000 1 000 25 000 25 000 5 000 5 000 29 000 29 000 7672 414 2200 000 315 000 315 000 Narrow face NF mold thickness with water channel mm Equivalent thickness of water box mm Mean temperature diff between hot amp cold face of NF C Cooling water channel depth mm WF NF Cooling water channel width mm WF NF Channel distance center to center mm WF NF Total channel cross sectional area mm 2 WF NF served by water flow line where temp rise measured Mold thermal conductivity W mK WF NE 1 60000E 05 Mold thermal expansion coeff 1 K 0 000 funnel height mm 0 000 funnel width mm 0 000 funnel depth at mold top mm 11 760 Machine outer radius m 11 985 Machine inner radius m 3 Number of mold coating plating thickness changes down mold No Scale Ni Cr Others Air Z positions unit 1 0 0100 1 000 0 100 0 000 0 000 0 000 0 2 0 0100 1 000 0 100 0 000 0 000 400 000 0 3 0 0100 1 000 0 100 0 000 0 000 800 000 0 0 550 72 100 67 000 1 000 0 060 Conductivity W mK MOLD THERMOCOUPLES 0 00E 00 Offset distance towards hot face mm 4 Total number of thermocouples No Distance beneath Distance below hot surface mm meniscus mm 1 19 50 1 00 2 19 50 20 00 3 19 50 121 00 4 19 50 226 00 80 Calculated Exit Conditions Initial casting speed 16 67 mm s Wide face simulatio
53. C poise 2500 00 Mold flux density kg m43 250 00 Flux absorption coefficient 1 m 1 500 Flux index of refraction 1 take default f composition 0 900 Slag emissivity 1 Form of mold powder consumption rate 1 kg m 2 2 kg t 0 411 Mold powder consumption rate 0 000 Location of peak heat flux m 0 000 Slag rim thickness at metal level meniscus mm 0 000 Slag rim thickness at heat flux peak mm 10 000 Liquid pool depth mm 8 00E 30 Solid flux tensile fracture strength KPa 8 00E 30 Solid flux compress fracture strength KPa 0 170 Solid flux Poisson ratio 1 number of slag static friction coeff data Next 2 lines contain zmm and Static friction coeff 0 0 0 400 0 400 Moving friction coefficient between solid flux and mold wall INTERFACE HEAT TRANSFER VARIABLES Number of distance vratio data points 1 constant ratio of solid flux velocity to casting speed Next 2 lines contain zmm mm and ratio data 5 000E 09 Flux mold or shell mold contact resistance m 2K W 0 500 Mold surface emissivity 6 000E 02 Air conductivity in oscillation marks W mK 0 0 400 4 500 Osc marks simulation flag 0 average l transient Oscillation mark depth mm Width of oscillation mark mm 1 3888890 Oscillation frequency cps 1 take default cpm 2 ipm casting speed 7 800 Oscillation stroke mm IMOLD WATER PROPERTIES 1 000 heat transfer coefficient W m 2K 1 default f T based on Sleicher and Rouse Eqn 41
54. CONID reads in the input file and starts running the simulation Warnings and errors that arise during the simulation are shown in the command window for that specific run The warnings and errors are not saved anywhere outside of the window so are lost when the user closes the window Running the program 19 not visually appealing and has a low user satisfaction 2 2 3 Reading Outputs Many output files of information are generated from running CONID There can be between 18 to 23 output files that are generated from running a single simulation The outputs include results such as shell thickness profile down the strand temperature profiles temperature histories taper predictions shear stress phase fractions and many other variables Previously the outputs were viewed by using Gnuplot to graph the data To plot the data users can use previously created scripts for Gnuplot that define which columns of data to plot on each graph The plotting program is not very user friendly for many reasons The user needs to run the program through a terminal window as shown in Figure 2 2 Es gnuplot JE File Plot Expressions Functions General Axes Chart Styles 3D Help Replot Open dave ChDir Print Prisc Prev Next GNUPLOT Version 4 2 patchlevel 2 last modified 31 Aug 2007 System MS Windows 32 bit Copyright lt C 1986 1993 1998 26804 2007 Thomas Williams Colin Kelley and many others Type help to access the on line reference
55. If users get into part of the system that doesn t interest them they should always be able to get out quickly without damaging anything e Provide shortcuts Shortcuts can help experienced users avoid lengthy dialogs and informational messages that they don t need e Good error messages Good error messages let the user know what the problem is and how to correct it e Prevent errors Whenever you write an error message you should also ask can this error be avoided 5 The new interface aims to achieve each of these heuristics It uses simple and natural dialog in many ways The buttons on the homepage are ordered from top to bottom and left to right to match the user s natural sequence The rarely used worksheets such as the spray table and grade table are not linked from the homepage but rather from locations that relate to each 25 table The intent is for an expert user to set up and customize these special features for a given casting operation prior to general use by all users in that operation The new interface aims to communicate information in the user s language As described in the user evaluation the spray zones are named as inner and outer radius zones to indicate the location of the zone using the most common industry expression for this concept Every parameter clearly describes the data to be entered in plain language rather than using an ambiguous Greek or other math symbol or codified label There is very
56. Metal Process Simulation Laboratory Department of Mechanical Science and Engineering University of Illinois at Urbana Champaign Urbana IL 61801 USER FRIENDL Y INTERFACE DESIGN AND DEVELOPMENT FOR CONTINUOUS CASTING MODEL CONID By Hemanth K Jasti amp Brian G Thomas Continuous Casting Consortium Report August 12 2010 ABSTRACT An user interface to input parameters run simulations and graph the outputs from the continuous casting model CONID was designed and implemented in a spreadsheet environment with a focus on including features to expand the usability and audience of the model CONID is a very powerful and efficient 1 D transient computational model of heat transfer in the process of continuous casting of steel slabs This model has been validated by many plant measurements to predict mold temperatures shell thickness mold heat flux slab temperatures and many other parameters This interface incorporates worksheets where the user can enter input data with user friendly features and functionality A grade table sheet allows the user to setup the composition of commonly used steel grades which can be used to automatically fill fields when running various simulations A spray table sheet allows a change in casting speed to automatically update water flow rates of all of the spray zones The user interface includes the key ability to convert the units of parameters allowing users to utilize either British units metric units
57. ONID calculate the parameters 48 Shell face to consider Mold face to consider Do you want 2D calculation in mold Max Distance below meniscus for 2D calculation z 2D calculation give more accuracy Time increment 5 3 00E 03 Start output at Max Simulation Thickness Max number of iterations 200000 Shell thermocouple number below hot face distance below surface Fraction solid for shell thickness location Is superheat treated as heatflux Do you want to print all files for related information for each slice Z distance for heat balance 849 000 Figure 5 17 Simulation parameters for full caster simulation 5 3 3 Mold Properties The mold properties page is input as shown in Figure 5 19 The cooling water temperature at the top of the mold is set to 43 C The water pressure is 0 62 MPa with a velocity of 8 5 m sec and running from the bottom to the top of the mold The mold water channels are set with a depth of 20mm 5mm width and distance between channels of 20mm and 22mm on the wide and narrow faces respectively There are no coatings on the mold used in this simulation 49 Slab Thickness Slab Width Total Mold Length 950 000 WE Mold Thickness with water channel outer rad top WE Mold Thickness with water channel inner rad top APA e S 0 0020 Grade Flag CK Simple Seg Model Cooling Rate for Seg Model Steel Liquidus Temp 1502 20 steel Density
58. Preset grade table worksheet A user can enter new preset grades and compositions by inserting a row under the last preset grade and entering in the name and compositions of the new grade Then the user will have to update the Grades box and click on the Update Preset Grades button to update the drop down menu with the new grade s After the preset grades are setup the user can select the wanted grade from the drop down menu on the Steel Slab Properties page When a wanted 17 grade 1s selected the preset compositions are copied over to the input parameters boxes A manual grade option is also available for the user to enter in any composition desired such as editing the composition of the standard practice grade to match the measurements of a particular heat 3 4 3 Spray Tables Spray Tables are very important set of data used in most casting operations These tables define for a given casting speed and spray pattern the specific water flow rates to apply in each spray zone which may be different on the inside and outside radius surfaces If the casting speed or spray pattern changes new water flow rates must be used for each spray zone For a simple casting speed change in a CONID input file the researcher would have to calculate water flow rates for each spray zone using the spray table data and manually enter the new numbers into the input file One of the key features of this program is the ability to incorporate spray
59. Shell temperature distribution out rso for full caster simulation 121 Output Steel Shell Temperature Below Surface 0 00 10 00 A 12 50 25 00 0 00 4 0 00 0 00 0 00 0 00 0 00 0 00 3 a L ka a a 5 md 600 4000 6000 8000 10000 12000 14000 16000 Distance Below Meniscus mm Distance mom below surface 0 00 10 00 12 50 25 00 0 00 0 00 0 00 0 00 0 00 0 00 0 0 e 10220 16220 10220 0000 10 2 1459 0 15226 15226 15226 00 00 20 1 esa R ol oo oo oo coco T 30 1 1398 2 16220 16220 1299 6 oo oo oo oo oo oo oo 40 1 ETH 16226 15226 15226 00 oo 00 00 00 00 00 50 0 1360 7 15226 15226 15226 00 00 00 oo oo oo oo 60 0 13398 1522 6 15226 18226 00 00 00 00 oo oof 00 70 2 1330 31 1522 6 1522 6 15226 00 00 00 oo oof oo 80 2 1622 6 1522 6 15226 00 00 ooj oof oof oof oo 90 1 Oe ie IS 6 00 00 oo oo oo 00 6 00 00 oo oo ooj oo 100 1 110 1 T Figure D 12 Steel shell Copre below surface out sst for full caster simulation 122 l t H dee 9 aunyesaduua Mold Temp cold amp Mold Temp hot MoldTemp hotcu A A dl o cella Ania n FF 77 SE ON 9 aunyesaduua Mold Temp cold Ak Tsurf Mold Temp hot Mold Temp hotcu M Z Dist Mold Thick Tsurt hot FITTI Coldface Twater Mold Temp cold old Temp Mold Temp 0 006 405325 14436 0 43 00
60. Transfer Variables Mold Water Properties Mold Geometry and Mold Thermocouples Previously users made changes to the input file directly using any simple text editor This type of interface does not allow for many user friendly features The example input files are very brief and contain limited information about the parameters This makes it hard even for researchers to fully understand the input parameters There exist many inputs which are entered in table format but are not visualized as a graph when using a text editor for editing A text editor is generally not visually appealing when entering data into the input file Different lines are hard to distinguish when entering large tables of information such as spray table data as shown in Figure 2 1 The data entered into the input file must be of the units used in the CONID program which are a form of cgs metric units SPRAY ZONE VARIABLES a 700000 Minimum convection heat trans coeff naturali CwmA2K right side inside radius 25 00000 water and ambient temperature after spray zone Deg Z spray zone condition fheat tran coeff Funct h A C wAnC1 b5T0 Nozaki Model 4 C 0 3925 n 0 55 b 0 00757 1 570000 AlO off O 5500000 n Fa 49990998E 03 b 11 Number of zones NO zone rol water pray contet frac of spra CD amb starts rad flowrate 1 length angle q thr rol vert coeff temp mmi Cwe mA Degc 1096 U 8 70 Zia 1250 210 FO 1767 2250 FO eae 2250 FO 3773 25
61. and temperature profiles assumed across interfacial gap 13 The user interface takes the values entered by the users and plots the viscosity curve against experimental values as discussed in Chapter 3 The viscosity curve liquid flux conductivity flux and steel velocity ratio and the slag static friction coefficient can all be entered as piece 42 wise functions of the distance down the mold for advanced analysis in studying mold heat transfer 7 9 This example illustrates a run for casting with mold flux For this simulation the solid and liquid conductivity are both 1 5 W mK The mold powder consumption rate is set to 411 kg m The other input parameters input into the interface page for this simulation are shown in Figure 5 11 Following Required for Mold Flux Casting Only Mold Powder Composition L Free Cl 0 00 Solid flux conductivity kasia Flux viscosity at 1300C 2372F Flux absorption coefficient Flux index of refraction Slag emissivity 0 900 Mold powder consumption rate 4 110E 01 kg m2 Slag rim thickness at metal level meniscus Slag rim thickness at heat flux peak Solid flux tensile fracture strength 8 00E 30 KPa Solid flux compress fracture strength 8 00E 30 kPa Solid flux Poisson ratio Moving friction coefficient between solid flux and mold wall Number of data points 1 2 Dist Tisol n e H TETI Experimental ALI 400 600 60
62. ater temp increase Deg C if above 3 1 Running mode 0 stop right now 1 continue to run positive integer ts run the program for ts seconds SPRAY ZONE VARIABLES 8 700 Minimum convection heat trans coeff natural W m 2 K right side inside radius 35 000 Water and ambient temperature after spray zone Deg C spray zone condition heat tran coeff funct h A C W n 1 bT Nozaki Model A C 0 3925 n 0 55 b 0 0075 1 5700 A O off 0 5500 n 7 500E 03 b 4 Number of zones No zone rol water spray contct frac of spray conv amb starts rad flowrate width length angle qthrrol coeff coeff temp zl Z2 z3 mm m I min row m m Deg W m 2K DegC 1 800 0 1 0 075 18 882 0 984 0 904 0 00 0 010 0 250 8 70 25 0 0 00 0 50 1 00 2 2000 0 1 0 075 9 187 0 984 0 050 10 00 0 080 0 250 8 70 25 0 0 00 0 50 1 00 3 2710 0 1 0 095 5 195 0 984 0 050 10 00 0 220 0 250 8 70 25 0 0 00 0 50 1 00 4 8700 0 5 0 095 3 897 0 984 0 050 10 00 0 200 0 250 8 70 25 0 0 00 0 50 1 00 14000 0 End of last spray zone mm 0 Consider Leidenfrost effect 1 yes 0 no 5 Number of points in the Leidenfrost effect curve if above 1 Next 2 lines contain Leidenfrost effect h multipliers and temperatures 1 0 2 5 1 8 1 3 1 0 500 600 700 800 900 left side outside radius 35 000 Water and ambient temperature after spray zone Deg C spray zone condition heat tran coeff funct h A C W n 1 bT Nozaki Model A C 0 3925 n 0 55 b 0 0075 1 5700 A O off 0 5500 n 7 500E
63. atflux Do you want to print all files for related information for each slice Z distance for heat balance Figure C 2 Simulation parameters for mold simulation 69 WF Mold Thickness with water channel outer rad top WE Mold Thickness with water channel inner rad top Ni_ 0 0000 Al 0 0000 V_ 0 0000 Cooling Rate for Seg Model ete cenar 100 TONE EA EA Steel Thermal Conductivity 26 00 Steel Thermal expansion Coeff 1 30E 05 Figure C 3 Steel slab properties for mold simulation 70 SPRAY ZONES Inner Radius o Patteme Lre spray zones E p e Spray Table Spray Zone Pattern Min convection heat transfer coeff natural Consider Leidenfrost Effect Number of Points on Leidenfrost Effect Curve Leidenfrost Curve points h multipiiers Temperatures 00 6001700500 900 Water and ambient temperature after spray zone A for Nozaki A 0 3925 for Nozaki c 0 55 g Ax Q ater A l bx Era b for Nozaki b 0 0075 Number of Spray A A Add Delete ones End of last spray zone o O Plant Zone Zone Zone Number Roll Water Spray Spray Contact brains a Name Number Starts at of Rolls Radius flowrate width na Cos q skei EDUN _ O Figure C 4a Spray zone properties for mold simulation Convection Ambient Coefficient Coefficient Temperature PST 0 250 szop 25 0 0 00 0 50 1 00 100 100 1 00
64. ation including the spray zones Many of the inputs and a few key outputs are displayed in this chapter as examples The complete inputs and outputs for these two examples can be found in Appendix C and D 5 1 1 Setup The user must first make sure that the interface excel file and the CONID executable file are in the same folder before starting the interface Then the excel user interface program 1s opened and macros enabled to let the program function If macros are not initially enabled explanations of how to do so are given in installation notes given in a pdf document which is also displayed in Appendix B The macros automatically setup many of the drop down options and bring the user to the homepage at startup 5 1 2 Homepage Figure 5 1 shows the homepage at startup There is a link to a help page which gives general help about the interface such as explaining the color schemes explained in section 3 3 The installation instructions regarding directory setup and macro security 1s given in Appendix B As can be seen in Figure 5 1 there are several different groups of general information that the 30 user must fill out on the homepage The first box upper left contains 4 lines of basic run information Company Name Run Title This information is entered into the 4 white fields of the input file to provide labels to track the basic information for this simulation Additionally the current date 1s also written into the input f
65. cel 2003 as both the development and final platform After much consideration it was decided that Excel is the best platform to reach the goals for this project Other considered platforms were C C Java and HTML These programming languages required a large amount of programming to create a user interface for CONID The largest weakness of these platforms is flexibility to allow changes by both users and future researchers The researchers and developers using CONID already know how to use Excel and can learn its macro language Thus 1t will be easier to change the interface to meet future updates to CONID Early versions of CONID also took an advantage of using Excel spread sheets 3 Licensing of special interface development software packages is not necessary A graphing tool kit is already included with Excel which greatly eases the complexity of the backend of the interface Since most users including plant operators already know how to use Excel they can readily change the graph output format styles views and titles as they please Also most users already have Excel installed and will not require any additional software or libraries to run the interface Excel 2003 was chosen over Excel 2007 as a result of compatibility issues The interface can run on both Excel 2003 and Excel 2007 The programming is done in Visual Basic for Applications VBA 10 CHAPTER 3 INTERFACE DESIGN AND FEATURES 3 1 Overview The new user interface
66. ct resistance EZ 000E 09 Mold surface emissivity 0 500 500 Air conductivity in oscillation marks 6 000E 02 Average Osc marks simulation flag Gama Oscillation mark depth Width of oscillation mark Oscillation frequency Oscillation stroke Figure C 8 Oscillation parameters entered for mold simulation 73 Flux viscosity at 1300C 250 00 a l Default 4 110E 01 ka m 2 Slag rim thickness at metal level meniscus e Slag rim thickness at heat flux peak 0 000 Solid flux tensile fracture strength 8 00E 30 Solid flux compress fracture strength 8 00E 30 Solid flux Poisson ratio Moving friction coefficient between solid flux and mold wall 0 400 Figure C 9 Mold flux parameters for the mold simulation 74 Trio and Viscosity Exponent n Number of data points 2048 Tfsol n 100000 aa fore es E Viscosity Experimental ALI 800 1000 1200 1400 Temperature Liquid Flux Conductivity Kiquid Tkliquid 0 4 0 5 0 6 Z distance below meniscus Figure C 10 Flux viscosity and liquid conductivity parameters for the mold simulation 75 Ratio of Solid Flux Velocity to Casting Speed V 4 Vo Number of data points 1 Solid flux velocity to casting speed 0 0 0 1 0 2 0 3 0 4 0 5 0 6 Of Z distance below meniscus Slag Static Friction Coe
67. d the user will be directed to the interface page from the casting condition page Oil casting simulations only require the first section of parameters because contact resistance oscillation marks and air gaps are the only parameters needed to define interface heat transfer when casting with oil lubrication Mold flux casting simulations require the user to enter data for the mold flux properties and all the other parameters in this page The oscillation and air conductivity parameters used for this mold simulation are shown in Figure 5 9 The second section of the Interface heat transfer parameters page includes many parameters regarding the properties of the mold flux such as composition solid and liquid conductivity viscosity and many others The model used to calculate the interface heat transfer is 41 illustrated in Figure 5 10 CONID uses equation 3 1 to calculate the viscosity of the mold flux from the viscosity at 1300 C the flux solidification temperature and an exponent n y p p Flux mold or shell mold contact resistance Mold surface emissivity Air conductivity in oscillation marks Figure 5 9 Oscillation and other parameters entered for mold simulation with detailed prediction of the interfacial gap solid liquid flux flux T Ts Ttsol Tis equivalent di t layer for em perature oscillation marks profile MAMAR RIN i V profile Ve ks l k oe ds 1d oef Figure 5 10 Velocity
68. ded that the user follow the order of input pages as listed on the homepage from top to bottom 5 1 3 Writing Running After entering all input data the next step suggested on the homepage is the final data check The data check certifies that data 1s entered in the required locations If data was not entered then the check will color yellow the parameter description and the button to the page Once the data clears the check all inputs buttons will turn green and the Write Input File button will turn blue to suggest the next step The Write Input File button 1s used to create the input file worksheet and the input files from the entered data The interface will create two files using the input file name entered on the homepage The first file is name inp which is the file with all the input data The second file is namein txt which is used to help run CONID from the interface After writing the file the Run CON1D button will turn blue to suggest the next step Click on this button to run the simulation of the name listed in the input file name box The black DOS window that appears is CONID running the simulation and will close automatically when the simulation is finished running The user should wait until the simulation is finished before reading the results into the output sections 5 1 4 Reading Outputs After the simulation 1s done the next step is to view the run time messages for the simulation It is recommended that th
69. e With the addition of this interface 1t is expected that the use of this software will expand to include more practioners including casting operators in the steel industry 1 2 Continuous Casting Continuous steel casting 1s the main processing method for most of the steel in the world The casting process is show in Figure 1 1 As shown in the image the continuous casting process begins with a large ladle filled with molten steel Ladle Tundish Submerged Entry Nozzle Meniscus Mold _ Liquid Pool Support Roll Metallurgical Length A Torch Cutoff MA May Solidifying Shell st Spray A Y d Cooling 7 Slab p lt LY Strand if i Figure 1 1 Continuous casting process 6 The molten steel is then poured into a tundish which is a buffer to allow for ladle changes without ceasing the casting process From the tundish molten steel flows through a submerged entry nozzle SEN into a water cooled copper mold The steel flow into the mold is regulated by either slide gates in the SEN or stopper rods in the tundish Once in the mold the steel begins to solidify against the mold surface to produce a solid steel shell with molten steel encased within The steel then exits the mold and enters a spray cooling zone All steel casters are curved with the two opposite surfaces of the strand referenced as inner right side and outer left side radius The spray coolin
70. e seen in Figure 3 2 11 Security Warning C Documents and Settings Hemanth My Documents Hemanth College Research Project UIcon1d001_00 xls contains macros Macros may contain viruses It is usually safe to disable macros but if the macros are legitimate you might lose some functionality ma Disable Macros i Figure 3 1 Excel 2003 with medium security setting Click on Enable Macros Da 9 gt Home Insert Page Layout Formulas Data Review View Developer B Arial 10 IN a ar General v paste y BUESA A E Z EF E IS gt 15838 Clipbo SJ Font fa Alignment CBI Number Sa e Security Warning Some active content has been disabled G5 ri fe Microsoft Office Security Options Y Security Alert Macros amp ActiveX Macros ActiveX Macros and one or more ActiveX controls have been disabled This active content might contain viruses or other security hazards Do not enable this content unless you trust the source of this file Warning It is not possible to determine that this content came from a trustworthy source You should leave this content disabled unless the content provides critical functionality and you trust its source More information File Path C 1 My Documents Hemanth College Research Project Ulcon1d001_00 xds Help protect me from unknown content recommended Open the Trust Center OF Figure 3 2 Excel 2007 Click on Options on the toolbar
71. e ve cee E A oe Gee Se ee Coots 9 De S O II A A i 10 CHAPTER 3 INTERFACE DESIGN AND FEATURES 11 EMO A II II NI AN 11 a is AAA A 11 AN O 13 OPE A A EEEE lella 15 CHAPTER 4 INTERFACE DESIGN ANALYSIS AND USER EVALUATIONS 29 A Heurn 1G ein ao 25 AZ User Evoa ONS rte T de 28 CHAPTER 5 USER MANUAL WITH EXAMPLE PROBLEMS 30 A A II AR 30 2 Mold S imolation Example cosa A a 33 5 3 Complete Caster Simulation EXample unit A eh 2 Ee TRN 5 4 CHAPTER 6 CONCLUSIONS AND FUTURE WORK ir iii 58 Ol OC LIS 1 ONS siti cscs a hee odes Meas Norte o tect steer ice lele 58 O2 el BAHN A ea 58 REFERENCES ict 60 APPENDIX A INPUT FILE FOR FULL CASTER SIMULATION sse eee 61 APPENDIX B INTERFACE INSTALLATION NOTES sse 66 APPENDIX C INPUTS AND OUTPUTS FOR A MOLD SIMULATION uu 69 APPENDIX D INPUTS AND OUTPUTS FOR FULL CASTER SIMULATION 109 CHAPTER 1 INTRODUCTION 1 1 Introduction There 1s a great need to create usable interfaces for useful engineering software tools Engineering software is rarely created using a user centered method but rather a function centered method oriented for the developer who is familiar with it Without the consideration of the users the actual software usage can be much lower than the potential benefits of the software The combination of increasing software complexity and the vast variety of users increases the gulf of execution the gap between a user s goals and t
72. ee 1 Metric amp British sec ein Y D o Factor to Multiply Factor to Multiply Factor to Multiply Mame Metric by to Convert to British by to Convert to Custom by to Convert to 20 ConiD units Con U units ConiD units 29 Length mm 1 in 25 4 Custom 1 3pletumet immer osta mm 1 mm 254 foam 1 30 channel inner amp outer mm 1 in 25 4 Custom 1 Figure 3 8 Layout of units worksheet 1 PIRI ROR KAKA IKAT O A S l lO MEA w Ro C LO 04M E ori There are multiple locations of common units such as distance found throughout the worksheet If the user wants to set all custom set temperature units to inches then all locations in the units worksheet that are distance related must be changed This allows for maximum customizability for a set of mixed units as mm might used in defining mold geometry while 22 inches are used for distance down the caster Once the user has customized the units as wanted the Update Units button must be clicked This will update all the unit factors throughout the workbook with any updates made within the unit s worksheet Users can change the units of a few special parameters casting speed variable casting speed time flux powder consumption rate and cooling water velocity flow rate individually with drop down menus without changing the units of the entire workbook These special parameters show their different unit choices vertically rather
73. es three parameters from the user to create viscosity at 1300C Tso and exponent n The temperature dependent viscosity profile is then calculated using Equation 3 1 n T_T u _ u 1300 fsol TT fsol 3 1 Often the user has experimental data for the viscosity profile and would like to input parameters to match their data As can be seen by Figure 3 5 the graph in the interface includes a set of cells for the user to enter experimental data and view it on the graph 16 Enter Experimental Data for Tfsol optional Number of data points Tfsol 100000 i i poise 2 700 10000 1500 3 f 30 05 1300 0 9 1260 pa 183 00 1000 1200 1400 Temperature Figure 3 5 Flux viscosity plot with the addition of experimental values This allows the users to edit the input parameters to match the experimental values by visually seeing the comparison between the inputs and experimental values 3 4 2 Preset Grade Table The input file requires that the composition of the steel must be entered To ease the work for the user the interface includes a feature to store commonly used steel grades and their composition into a worksheet When needed these preset compositions can be chosen by a drop down menu in the steel slab properties Figure 3 6 shows the preset grade table used for this user interface Grade Name C Mn S P Si Cr Ni Cu Mo Ti Al wv N Nb W Co Figure 3 6
74. ese messages be read before reading in the rest of the 32 outputs The run time messages include information about any warnings or errors that may have occurred in CONID while running the simulation After viewing the run time messages it 1s suggested to read in the outputs Since most users will not look at every output from CONID the interface allows for only reading in outputs the user requests The user must first check the box es of all outputs to read into the program and then click the Read Outputs button The interface will read in the data into the output pages and re plot the output graphs Once an output page 1s successfully read in the link button to that page will turn blue on the homepage The user can then examine the output by clicking on the button from the homepage The user can change the axis ranges and most other graph options as wanted The user must not delete any plotted data line on the graph as this could lead to an unstable platform The user can also view the predicted thermocouple data on the exit conditions page Beside the thermocouple data there 1s a column for the user to enter in experimental values to enable easy comparison against the model which is essential during the calibration phase of running CONID 5 2 Mold Simulation Example The mold simulation demonstrates how the user interface can be used to conduct a simulation with CONID using mold flux casting parameters to calculate heat transfer in t
75. exit LatentHeat mold exit Super Heat Z bal Sensible Heat Z bal _ LatentHeat Z bal Heat kJfm 2 __ r I I I E d n e e m e e m m L a m e e e m e e I I I I I I I I d I I I I I I I I I 4 I I I I I I I J I I I I I I I I d I I I I I I I I I 1 I I I I I I I Etnica SEL SURE ne A 80 ho oo E D Distance into Shell mm Temperature distribution and heat balance at 849 0mm 12 05 Sensible Temperature Super Heat Heat aca Latent Heat Distance i 0 0000 1161 7 12 ea 1002 7 1161 2 at al seo mer 0 5000 1002 7 1 0000 MES E ELE ro aa er 10027 1 5000 dd is E 177 1007 Figure D 10 arn erae and heat balance out prf and out of for full caster simulation 120 Shell Temperature distribution 2000 280 4000 267 6000 34 8000 298 10000 255 Temperature C 12000 212 14000 368 5000247 40 50 60 FO Distance Below Meniscus mm 80 d Distance Temp Temp C 1 mm ls 0 0000 7 MIT IT Wed nim G OJ 1081471 2000 280 30 100 amp ZDist Time 2000 280 30 100 0 5000 1 0000 A 1100 93 1 5000 2 0000 A ma 2 5000 3 0000 3 5000 4 0000 4 5000 45 1183 62 5 0000 5 1198 86 5 5000 5 5 1214 34 6 0000 6 1229 95 C CANN ANAC CO EE ATA CO Figure D 11
76. fault option 1s available for the max simulation thickness to help prevent a different number in the slab thickness if that was not specifically intended by an expert user To prevent users from arriving at unwanted sections of the interface navigation 19 desired to use only buttons for general users just running the program Special worksheets such as the 27 input file data worksheet are only accessed using tabs because only experts should be viewing these worksheets As shown by the examples above the nine heuristics have been incorporated into the interface The future iterations of the interface will continue to use these guidelines to help design and progress the interface 4 2 User Evaluations Researchers in the Metals Simulation Laboratory and researchers in the steel industry were asked to evaluate the interface and comment on the usability of the program A few different usability problems were found as a result of these user evaluations One inexperienced user found that changing the parameter of slab thickness entered on the Steel Slab Properties page did not result in the slab thickness change in the simulation he expected The Slab Thickness is required in two different locations on the input file for CONID once under the header Simulation Parameters called Max Simulation Thickness and once under the header Steel Slab Properties called Slab Thickness For most cases both of these input parameters should be the same For ex
77. fficient e Friction Coef a iTi Les LH Sa Sa Sa SS iction Goefficient Pa NR NR amp mul 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 Z distance below meniscus Figure C 11 Flux velocity and slab friction parameters for the mold simulation 76 Table C 1 Interface generated Input File Sent to CONID CONID 9 7 1 Steel Continuous Casting Heat Transfer Analysis UI Version 07 09 2010 University of Illinois Brian G Thomas University of Illinois Hemanth Jasti 15 Jul 2010 Mold simulation example 1 Parameters to update every call IICASTING CONDITION 1 00 Number of time cast speed data points If 1 constant casting speed Next 2 lines contain time s and vc m min data points 0 0 1 000 1550 000 Pour temperature C 94 000 Distance of meniscus from top of mold mm 265 000 Nozzle submergence depth mm 1000 00 Max simulation length must gt z distance mm 0 Calculate mold and interface 0 flux casting or 2 oil casting or enter interface heat flux data starting at meniscus z 0 1 or enter avg mold flux 2 or enter cooling water temp increase 3 7 Number of zmm and q data points if above 1 Next 2 lines contain zmm mm and q kW m2 data 0 00 100 00 200 00 300 00 400 00 600 00 800 00 2910 00 1840 00 1580 00 1390 00 1260 00 1000 00 880 00 2 500 3 500 Average mold heat flux MW m22 if above 2 2 30 0 07 0 40 Mold flux tuning parameters q_fac tc_fac q_n if above 2 7 000 5 000 Mold cooling w
78. for CONID uses Excel as the programming platform The interface is programmed in VBA through macros in the excel file This interface is divided into different worksheets for inputs and outputs The inputs and outputs are organized as similar as possible to that of the text input file This allows for a faster learning curve for already experienced users of CONID The inputs are broken up into seven different worksheets Casting Conditions Steel Slab Properties Spray Zones RS Spray Zones LS Mold Properties Thermocouples and Interface The outputs have a designated worksheet for each of the files written by CONID The user interface opens to a homepage worksheet which links to all input and output pages The homepage also contains the buttons for major functions such as checking data writing the input file running CONID and reading in the outputs 3 2 Starting the Interface To be able to use the interface as intended the users must be able to enable macros when opening or before opening the file The interface is not usable if the security settings are set to not allow the macros to run If using Excel with a low level of macro security the macros will be enabled when the file is opened Using Excel 2003 with medium security requires clicking the Enable Macros when opening the interface file as shown in Figure 3 1 Ifusing Excel 2007 or higher the macros can be enable by clicking the Options on the toolbar and enabling macros as can b
79. full caster simulation 114 Initial casting speed Carbon content Wide face simulation The following 3 temperature from Y M Won Segregation Model Parameters Based on Derived Mold Values Carbon equivalent using initial casting speed e percent neq Cooling water velocity Cooling water flow rate per face assuming flux moves at casting speed Max hot face temp eco Y Max hot face temp ating kr Figure D 8a Calculated exit conditions out ext for full caster simulation 115 Heat Balance at 849 03mm Heat Input to shell inside C d Figure D 8b Calculated exit conditions out ext for full caster simulation 5 mm ick Ss Ham Solid flux film thickness Total flux film thickness 116 Distance Distance Predicted Experiment Thermocouple beneath hot below Number sumac meniscus Lowe ool E 114 07 13651 O y y y ogof 2000 69758 Oo TT oeo s000 4638 O sp oso 2000 69758 O lt a oa 1000 9 13 O i 090 oeo vo 1365 ony y oeo zooo 20874 pt 10 80 30 00 218658 i 4 10 80 Tooo 200291 i te 10 80 100 00 17787 O vr oso 12000 167268 10 80 14000 159285 10 8 170 0 10 80 200 00 978 10 8 250 00 10 8 300 00 10 8 400 00 500 0 790 U DIO 20 0 so aol 3 _ T L E si I O sit oo ol rt 15 60 120 00 120 84 eden a seol 200 00 mozo se E E e A 40 15 80 30000 3TA A 4 15 80 50000 9049 B
80. g zone consists of many rows nozzles spraying water to cool the steel and support rolls that act as a girdle to keep the shell from deforming Once the steel 19 fully solidified the slab 1s cut to desired length and moved to other processes 6 The most important phenomenon that governs this process 1s heat transfer 1 3 CONID The complexities of the casting process led to the use of modeling tools such finite element finite difference and computational fluid dynamics to understand and improve the process Professor Brian Thomas and graduate students at the University of Illinois Urbana Champaign created a computational model to simulate heat transfer in the continuous casting process called CONID 3 8 The model uses a 1 D transient finite difference method to calculate the heat conduction in the liquid pool the solidifying steel shell and the mold from the start of solidification at the meniscus until after cutting into final slab and billet product The governing equation given in Equation 1 1 dictates the heat conduction from the steel and accounts for both sensible and latent heat of the steel P Cp T T Zizi OT 1 1a steel P ai Or steel dx OT Ox la _ dH d Where C C L 1 1b dT dT CONID has the ability to use a coupled 2 D steady state heat conduction model in the mold wall CONID does detailed analysis of the interfacial gap in the mold with mass and momentum balances on the slag layers and effect
81. ge users work must not occur The system should enable users to recover from errors e Satisfaction The system should be pleasant to use fostering subjective satisfaction in use 11 3 These components must be considered when designing an interface for increased usability These attributes of usability are commonly measured through user testing but can be measure using various methods of analysis such as Cognitive walkthrough and Heuristics Analysis Analyses such as GOMS Hick s law and Fitt s law can also be used to retrieve qualitative results related to estimating task completion time Results from these evaluations and user tests can be incorporated into an iterative improvement process to further increase the usability of the system 11 The design process should involve the contribution of users with knowledge of the context of the interface Participatory design views the users as key innovators and design contributors since the users themselves know best what are the tasks and frustrations that can be solved through the interface This project creates an interface to help bridge the function centered core of a heat transfer model of continuous casting of steel called CONID to a user centered software tool It takes a participatory design approach as several avid users of the software provided input Many researchers at the University of Illinois and researchers and engineers at steel companies currently use the softwar
82. he mold 7 5 2 1 Casting Conditions The data sets to enter are the casting condition parameters The casting condition page has two sections casting conditions and simulation parameters The casting conditions include the casting speed pour temperature distance of meniscus nozzle depth simulation length and 33 shell mold interface heat transfer This example uses a constant casting speed of 1 00 m min and other casting condition parameters as shown in Figure 5 2 Enter Casting Speed 1 00 mrin m Update spray zones T Varying Casting Speed rom spray table Pour Temperature 1550 000 TT Distance of Meniscus from top of mold 94 000 Nozzle submergence depth Max Simulation length 1500 00 SLI How to calculate shell mold interface heat transfer CONEA calculate interface heat based on mead Au UCH HERE to enter heat flux daa and mala iu properties bath sections Figure 5 2 Casting condition parameters for mold simulation The option to choose How to calculate shell mold interface heat transfer is a very important parameter that greatly affects what data the user needs to enter to define mold heat transfer Each option prompts a button to link the user to the correct location to enter the appropriate information for the specific choice Choosing either oil casting or flux casting prompts a button to link to the Interface heat transfer parameters page where the user must enter a
83. he means to execute these goals 10 This need to reduce the gulf of execution and increase usability led to new approaches of interface design from the viewpoint of a user rather than functionality 2 The user center design UCD method concentrates on creating interfaces with greater usability by understanding the goals and tasks of the users and creates a tool that improves its usefulness and reduces the user stress 11 User center design must follow certain principles to adequately be applied The process requires properly deciding functions that the system should handle and functions that the user will handle A usable interface will give control to users when needed but also be able to automate tedious tasks Reducing steps and making actions clear and understandably also increase the usability of the software The usability of an interface can be explained by the following five components as described by Nunes e Learnability the system should be easy to learn enabling even inexperienced users to perform rapidly the supported tasks e Efficiency the system should be efficient in use so that once the user has learned the system he should be able to achieve a high level of productivity e Memorabilty the system should be easy to remember allowing casual users to reuse the system without having to learn the system again e Error Prevention the system should prevent users from making errors in particular errors that dama
84. he phase fraction evolution in the mushy zone more accurately With choosing the option of the segregation model a cooling rate for the model must also be entered The thermal properties of the steel can be set to a constant number or the default option can be chosen which allows CONID to calculate the parameters Slab Thickness 230 100 Slab Width 1500 000 Total Mold Length 894 000 WF Mold Thickness with water channel outer rad top WF Mold Thickness with water channel inner rad top Co 0 0000 3 g Mode i Ji ess RI oo Steel Specific Heat 058 Steel Thermal Conductivity fi emer E MO Steel Thermal expansion Coeff 1 3 Figure 5 4 Steel slab properties for mold simulation E 37 5 2 3 Mold Properties The mold properties page includes information related to the mold geometry mold cooling water and mold coating The mold cooling water can be entered as either a flow rate or a velocity The user must first choose the preferred units from the drop down menu then enter the appropriate numbers below The mold cooling water flow direction must also be set by choosing the option of bottom to top or top to bottom For this simulation the mold cooling water is set to a pressure of 0 202 MPa and a velocity of 7 8 m s from top of the mold to the bottom for both the wide and narrow face The mold geometry is entered using this page Funnel shape can be entered for thin slab casters with funnel mo
85. ictures In the next three slides University of Dlinots at Urban C tampi N Metas Processing Simulation Lab Starting the Interface Office 2003 s Enable macros at start by choosing Enable Macros Security Warning Tipa mena sd nan Te Dea nre b land Llamm araa cH Project Lioni dL Midi canbani RI TOS Hare PRJ contar vos IEL asd cola te drade raras bar E Eba mer sare da sou right ca coma fund ioral If security setting is set to high change security settings by follow steps x Tools gt Macro gt Security s Choose Either Medium or Low Reopen interface file and Enable Macros University of Dlinots at Urban Campa S Metals Processing Simuiation Lab 67 i wn a ST ating Cansortium TE TE Tatma hate Aa mia a CREARA SS Cee n vira 23 Caria to te sy er L Click on the Options button to enable macros a Select Enable this content Universzy of Dlizos at Urbanz Champezo Starting the Interface Office 2007 Orvetesr Me rT Office Sar varT Options D Security Alert Macros amp ActiveX Macros A Actie t MIO ad or or O A CTA LAE Sem Tis Ta SR content En rane mast n ober ann NT ar Or ner mobles tun sereni PERAE Vi tint Tre LAIA o Pu he Waramg N th sot povmuble to detrmmene that thes costent came wom a trestworthy source Vou should eave the content Mira bled undess the content provides CET functioeatty and you innt ita source
86. ile in the same line as the Company and Name for future reference Compan University of Illinois Run Title Almost whale test Name of input file CADocuments and Settings User My Corey bi Documents Research Project Enter Input ite Input File Segregaticn Sed Properties Daa Pre solid Aux Brest _ Phase Fractions rG CON1D Version CON1D 9 7 1 Interface Version UL Version 07 18 2010 Sigd hse Cencentrsion 1 Acvenced hits Setup Examine Output Run Time Messages Cutouts Shel Terp Profile Pr Taper Ter Shell Terp ea Wald Flux Velocity o Sheer Stress in Gap Shr o Licuid Phase Ceoncentracn 1 Lid Sd Figure 5 1 Homepage at startup dic Phase Concentracn 2 41 Select All Select Mone Shel Sh Steed Shel Thrmepl Cita Sst bold Flux Cep pt Hus Temperature Ucuid Phase Concentracn 2 La Next the user must choose a set of units to user for the parameters There are three sets of possible units Metric British or Custom The Advanced Units Setup takes the user to the 31 customizable units worksheet which can be setup or modified by an advanced user as explained in Chapter 3 It is highly advised that the user choose the unit system before entering parameter data or reading in outputs Once the unit set is chosen and general information is entered the user can proceed to the various input pages It is recommen
87. izable units to let users choose metric British or a mix of both unit sets The fully customizable units choice allows for a much greater chance of acceptance of CONID within the United States of America due to the extensive use of the British unit system The user interface runs CONID transparently from within the commercial spread sheet program Microsoft EXCEL instead of requiring the user to create a DOS window The new interface allows the user to read and graph simulation output data very easily Initial feedback from user evaluations showed a positive review about the system with a few usability issues The user feedback was used to improve the system and increase the usability The system is now ready for use by a wide range of users including those at the steel plant who are not familiar with heat transfer or modeling 6 2 Future Work There are still features that can be added to improve the functionality and usability of the interface Users of the interface often use CONID to extract steel property data for input into other models such as ABAQUS A feature should be added to output the property data in the 58 format needed for this program There is also a need for users to be able to compare two different CONID runs on the same graph Dual run graphs increases the ability to do parametric studies using CONID For this a new post processing system needs to be created to handle displaying the information of two outputs at the same time
88. ld Gap in Continuous Casting of Steel Diss University of Illinois 2004 Meng Ya and B G Thomas Heat Transfer and Solidification Model of Continuous Slab Casting CONID Metallurgical and Materials Transactions 34B 5 2003 pg 685 705 Meng Ya and B G Thomas Simulation of Microstructure and Behavior of Interfacial Mold Slag Layers in Continuous Casting of Steel ISIJ International 46 5 May 2006 pg 660 669 Norman D A The Design of Everyday Things New York Doubleday 1990 49 52 Nunes D N J Object Modeling for User Centered Development and User Interface Design The Wisdom Approach PhD Thesis Universidade de Madeira 2001 Santillana B L C Hibbeler B G Thomas A Hamoen A Kamperman W van der Knoop Investigating Heat Transfer In Funnel Mould Casting With CONID Effect of Plate Thickness ISIJ International 48 10 2008 pg 1380 1388 Thomas B G CON1D Users Manual Version 9 7 Continuous Casting Consortium Report 2009 60 APPENDIX A INPUT FILE FOR FULL CASTER SIMULATION CONID 9 0 Slab Casting Heat Transfer Analysis University of Illinois Brian G Thomas 2005 Input Data 1 Parameters to update every call CASTING CONDITION 1 Number of time cast speed data points If 1 constant casting speed Next 2 lines contain time s and vc m min data points 0 3 9878 1553 000 Pour temperature C 100 0000 Distance of meniscus from top of mold mm 150
89. lds which affects the taper calculation The cooling water channel depth den with channel width Wen and distance between channels La are defined as shown in Figure 5 5 This simulation uses a mold with water channel depth of 25mm width of Smm and a distance of 29mm from center to center of adjacent channels To estimate the narrow face mold distortion the thickness of a beam that 1s equivalent in rigidity to that of the water box 1s entered along with an estimate of the temperature difference expected The total cross sectional area of all channels in a mold face is used to relate measured water flow rates with average channel velocity The other mold parameters are shown in Figure 5 6 The mold coating plating thickness table is used to input the thermal conductivity and thickness of any coatings on the hotface of the mold The thickness data entered defines a piecewise linear function of distance down the mold for each coating by connecting the data points The table for the mold coating plating thickness allows for a maximum of 20 data points The value entered in the Number of mold coating plating is the number of data points 38 written to the input file regardless of how many data points are entered into the table The entered values for the Mold Properties for the mold simulation are shown in Figure 5 7 Tcold Thot bolt Y Y wch hot i e steel coating layers Y
90. ll RHS dc L L E a E m 600 800 Distance into Shell mm Figure C 13a Shell thickness and temperature out shl for the mold simulation 83 9 S E E 600 800 1000 1200 Distance into Shell mm Positon lx RHS a wee RHS ee RHS aT LHS Tsprime s Li 0 00 0 0000 ____ 10 00 Tone 1223 maze 20 00 aan sof tel RI moi 13 IR 30 03 40 03 50 03 60 03 70 03 80 03 90 03 100 03 110 03 120 03 130 03 140 00 150 00 9 0000 8 53 6 30 7 50 7 50 1120 7 11954 1195 4 Figure C 13b Shell thickness and temperature out shl for the mold simulation 84 4 Temperature mold exit Temperature Z balance Temperature C 15 20 Distance into Shell mm 4 Super Heat mold exit a Sensible Heat mold exit Latent Heat mald exit Super Heat 2 bal Sensible Heat Z bal Latent Heat 2 bal Heat kJ m 2 100 150 Distance into Shell mm Ce E use tomi 1 5007 osa T oeral ioa Figure C 14 pen Profile and heat balance out prf and out pf2 for the mold simulation 85 Shell Temperature distribution 2 L k deg a E LE 100 150 200 Distance Below Meniscus mm mp Ep mm Distance Temp Dist Time mm Temp C mm Time s Of 1183 07 1000040 60000 250411 1215 22 35015 1228 26 5 5024 1254 77 5 5024 1254 77 Figure C 15 Shell temperatu
91. m Figure 5 25a Predicted shell thickness in the mold for full caster simulation Shell Thickness Entire Run A L a m m o F Shell RHS EP Shell LHs Shell Thickness mm 4 4 p 4 4 P AAA n sl a e e e ee a m m I I I I I I I I T I I I L I I I I I I I I T I I I 2000 4000 5000 2000 10000 12000 14000 16000 Distance into Shell mm Figure 5 25b Predicted shell thickness for the entire run for full caster simulation 56 Lw lt E E a o H E l TE LH m 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 Distance Below Meniscus mm Figure 5 26 Hear transfer in spray zone below the mold for small section of full caster simulation 57 CHAPTER 6 CONCLUSIONS AND FUTURE WORK 6 1 Conclusions A new user interface for the simulation software CONID has been designed and created This graphical interface includes many user friendly features that are a great improvement over the previous text based interface used Graphs in the input parameters helps users visualize data they are entering A preset grade table gives users the ability to setup the compositions of commonly used grades and be able to choose from the list at a later time The new interface can automatically change water flow rates for a simulation from provided spray tables casting speed and spray pattern choices The interface incorporates fully custom
92. manual The gnuplot FAQ is available fron http www gnuplot info fagq Send bug reports and suggestions to http sourceforge net projects g plot gt erminal type set to windows gnuplot call g shr readout_test fFilews_test _ Figure 2 2 Gnuplot interface Gnuplot plots one graph then overwrites the plot with the next graph when prompted To view multiple graphs simultaneously requires running multiple instances of Gnuplot and importing viewing the results elsewhere This program does not allow the user to easily change the graph axis or data names as he would like To personalize the graphs the user needs to know how to change the Gnuplot scripts accurately which has a limited and difficult scripting language The output 19 limited to viewing the final data only in units used by CONID which may not be the preferred units of the user 2 3 User Studies The user interface created in this project was designed to be used by various types of people The majority of the users are researchers in both the industry and at the university Many of the current researchers are already experienced in using CONID through pervious interfaces They understand most of the theory behind the input parameters and the information required for different types of simulations In addition to the experienced researchers many other researchers have never used the CONID software These researchers can be categorized as new users of the program but
93. n The qu 3 temperature from YM Won Segregation Model Sold Temp 1485 OfDege r BET TE Farameters Based on Derived Mold Values Carbon equivalent using initial casting s Negative strip time as Positive strip time o li 5 Cooling water velocity mis Ri Cooling water flow rate per face 59 6446 i if Average mold flux thickness assuming flux moves at casting speed min heat trans coeff on mold cold face Ca max heat trans coeff on mold cold face Water boiling temperature 154 Wim2k lt Wim2k C 290 Se suc oss oe gt DegC D i oe i 8 0775 De 6 6069 Ma D Warning There is danger of boiling in Degt the water channels tace temperati JITE Fint tar tira iot tace temperatur Malal 1411 97 MAT 1 41E 03 kWW m 2 Heat Balance at 20 00mm Heat Extracted 0 o v ym _____ MS Mime MJ m 2 ut to shel inside TO y region M T 0 02 vm m2 Cooling ui o CE MJ m 2 o im 2 ens C 12a Calculated exit conditions out ext for mE mold simulation SI Heat Balance at Mold Exit 800 03mm J Shell thickness Figure C 12b Calculated exit conditions and thermocouple data out ext for the mold simulation 82 Shell Thickness in Mold Shell RHS E Shell LHS Shell Thickness mm 400 600 300 Distance into Shell mm 4 LigLocRHS A4 SolLocRHS amp _ She
94. on 5 1 4 the mold thermocouple temperatures shell thickness and spray zone data can be examined The user can view the predicted thermocouple data on the overview mold exit ext page There is a column for the user to enter in experimental values next to the model values for comparison as shown in Figure 5 24 beneath hot Thermocouple Number Figure 5 24 Predicted thermocouple temperatures in exit conditions output for full caster simulation The shell output page shl includes data relating to the shell thickness solid and liquid locations and shell temperatures The shell data is shown in two different graphs as shown in Figure 5 25 The graphs to the left have a smaller Z distance on the x axis to be set by the user as the mold length The graphs to the right show the shell thickness for the entire simulation The 55 spray zone spr output page includes the various types of heat transfer out of the steel in the spray zones The heat transfer by air convection radiation sprays rolls and total heat transfer are listed Figure 5 26 shows the graph from this page Ever peak in the graph shows a location of either a spray or roll where a large amount of heat leaves the steel shell Thickness in Mold Shell RHS AB Shell LHS Shell Thickness mm I I I i I I I I I I I I T I I I d I I I I I I I I T I I I i I I I I I I I T I I I 200 Distance into Shell m
95. ost common English Units used The custom units can be setup to any unit system desired 20 All three sets of units can be defined or edited on the Units worksheet The Units worksheet defines the units of all the parameters in the inputs and outputs The worksheet 19 broken up into sections by each worksheet that is used for input or output data Within each worksheet section similar parameters are grouped together under one parameter name Each parameter or group of parameters has three pairs of unit name and conversion factor One pair relates to the Metric Units set one to the English Units set and the last pair to the custom units set Each parameter or group of parameters 1s customizable to be set to any unit for each unit set by the user The user first enters the appropriate unit name eg inch into the cell under the desired unit set name column eg Custom and unit name row eg Distance Then the factor needed to multiply the parameter input to convert to CONID units is entered into the cell beside the unit name For this example the CONID unit is mm so the user wanting to use inches must enter the factor 25 4 The units worksheet is shown in Figure 3 8 A special case arises for temperature units Temperate units require not only a multiplication factor but also a constant factor to be added The formula used to convert temperature units is shown in Equation 3 2 PAS lassi E i ition AA 3 2
96. ow rate instead of area and weight The units for the spray table are given as an option on the spray table worksheet The spray table units are independent from the rest of the interface and can only be changed from the spray table worksheet 24 CHAPTER 4 INTERFACE DESIGN ANALYSIS AND USER EVALUATIONS 4 1 Heuristic Analysis Heuristics are guidelines to help make interface design decisions At the early development of the user interface design discipline many researchers compiled short and long lists of heuristics that should be followed in interfaces The most commonly used set of heuristics today were developed by Nielsen and Molich 5 Nielsen and Molich created an evaluation procedure and a short list of nine key heuristics to consider Nine Heuristics by Nielsen and Molich e Simple and natural dialog Simple means no irrelevant or rarely used information Natural means an order that matches the task e Speak the user s language Use words and concepts from the user s world Don t use system specific engineering terms e Minimize user memory load Don t make the user remember things from one action to the next Leave information on the screen until it s not needed e Be consistent Users should be able to learn an action sequence in one part of the system and apply it again to get similar results in other places e Provide feedback Let users know what effect their actions have on the system e Provide clearly marked exits
97. perts interested in the mold only where the shell is always thin the computation speed is greatly increased by setting the simulation domain to less than the maximum thickness in order to avoid needless computation in the liquid pool The results are the same so far as the shell thickness remains less than 2 3 of the domain size Inexperienced with the input file the user did not know this information To address this issue a default option 1s available for the Max Simulation Thickness under the Simulation Parameters This default option will set the Max Simulation Thickness equal to the Slab Thickness If the user changes the Slab Thickness to a value not equal to the Max Simulation Thickness a message will alert the user of the 1ssue 28 One user found that he switches between the spray zone inner radius worksheet and the spray zone outer radius worksheet often The buttons on the page allowed for the user to go back only to the home worksheet which then can link the user to the opposite spray zone worksheet To increase the usability of the interface two buttons one button was added on each spray zone worksheet to link to the opposite spray zone worksheet The naming convention of right side and left side spray zones is ambiguous to those familiar with continuous casting Most users refer to both the mold and spray zones as either inner radius or outer radius To increase the usability of the program the titles and buttons were changed to
98. pt for the mold simulation 96 E E n pl _ g rf BE LL g 3 E LU 400 500 600 700 200 Distance Below Meniscus mm IC O lt pos pose hrad dist hrad hcond dsolid dliquid deff dtotal viscosity dist m Im K Figure C 21c Effective flux thicknesses for heat transfer out gpt for the mold simulation 97 Mold hot face Steel surface Mold hot face Steel surface T5 TF I a I daltesrgsiilti i u_u dd E 2 F 3 d E E O e I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I T I I I I I I I I I I I I I I I T I I I I I I I I I I I I I I I I I I I I I I I I 1 I I I I I e e ee ee ee ee ee eee ee eee E I emma 4 fold hotfaa__t2_ T2_ t3 713 M Figure C 22a Flux temperature histories out fxt for the mold simulation 21 t1 1400 9 arad ua xnj4 9 aunqesachuay xna i 3 2 L 2 L E J E L 2 E E E E Y pe E Dist Figure C 22b Flux temperature histories out fxt for the mold simulation 98 Axial Stress in Solid Flux Layer 4 0E 06 3 5E 06 I I I I I I I I I L I I I I I I I I I I I I I r I I I
99. re distribution out rso for the mold simulation 86 Output Steel Shell Temperature Below Surface 3 T k S e a a 5 Tw 600 800 Distance Below Meniscus mm E n UT J a D j S 10 oof 1521 6 15216 1521 6 15216 00 00 00 00 000 00 0 0 A 10 0 14429 15216 15216 15216 000 00 00 0 0 oy oo 00 20 0 13956 15216 15216 15216 000 00 00 00 00 00 0 30 0 13631 15216 15216 15216 00 00 00 00 000 ooj 0 0 _ 40 0 1336 8 15215 15216 15216 00 00 00 00 00 00 00 ___ 50 0 13151 15215 16215 15216 00 00 00 00 000 ooj 00 ___ 60 0 12965 15215 15215 15216 00 00 00 00 000 00 00 ___T00 12802 15214 15215 15216 00 00 00 00 000 00 00 ann 19RE A 1891 A 1891 E 469718 non no non non non nn no Figure C 16 Steel shell temperature below surface out sst for the mold simulation C3 i 87 Temperature C 200 100 100 200 300 400 500 Distance Below Meniscus mm z GUD _ E a a E a gt Distance Below Meniscus mm suf MoldTemp hot _ Mold Temp hotcu Mold Temp cold MASS Mold Temp Mold Temp Mold Temp PTE Thick e hot hotcu cold ir hwater _ _q _ _ _ o 18750 7 a EE IR E A 18750 7 of A oof a il sro ooj om 58 S Figure e 7a Mold data au t mld for the mold o 88 I I I I I I I I I I I I I I I I I i I I I I I I I I I I I
100. rties out prp for the mold simulation 101 E TE kh LL di w E a 1100 1300 1500 Temperature C _ Alpha fa Gamma fg 8 Delta fd Liquid fl Figure C 24b Steel properties out prp for the mold simulation 102 0 9 08 OF 0 5 4 0 4 03 0 2 0 1 1400 1420 1440 1460 1480 1500 1520 E Lx ro E _ a wi 5 E DL Temperature C gt T Alpha fa _ Gamma fg Delta fd Liquid fl Figure C 24c Steel properties out prp for the mold simulation 103 Local solidification time sec Distance Below Slab Surface mm Cooling Rate K sec Distance Below Slab Surface mm i od Ba ee Distance SDAS 0 0000 5 177 6013 10 3259 1465 4734 0 5002 61 pe Ir Beal 3073 Figure C 25a Secondary dendrite arm spacing and solidus temperature from segregation parameters out seg for the mold simulation 104 secondary Dendrite Arm Spacing um 5 10 15 20 Distance Below Slab Surface mm 2 nt Lk Pal De nt amp E pak qn o un 10 15 20 Distance Below Slab Surface mm Figure C 25b Secondary dendrite arm spacing and solidus temperature from segregation parameters out seg for the mold simulation 105 10 00mm below surface Phase Fraction Temperature C 600 600 Distance Below Meniscus mm E Liquid Delta Gamma Alpha Temp Shell S
101. s of the oscillation marks 8 The model can predict the steel shell thickness temperatures histories temperature profiles mold temperatures mold heat transfer flux temperatures thicknesses and velocities of mold flux shell mold gap properties spray zone heat transfer steel properties phase fractions and many other related parameters CONID uses many inputs that describe the casting and cooling systems used for a specific caster The model needs to be calibrated to each caster and validated before the model can be used with confidence Once the model parameters are calibrated the model can be used as a research tool for the specific caster This model can be used in a wide variety of ways to help design continuous casters or run studies on current casting operations to help improve quality efficiency and to investigate the consequences of proposed process changes Many properties can affect heat transfer in casting machines using this model parameters such as casting speed flux powder type and mold oscillations can be studied independently This software can be used to help learn conditions that may have led to severe problems such as whales cracks and other defects The software was previously used to study the slag and gap between the mold and steel 9 CONID is a powerful tool that can be used in many ways to help the steel continuous casting industry The model is a fast robust code written and complied in FORTRAN The success and
102. table data to automatically create the appropriate input data for the simulation If the user chooses to use the spray table data the program will automatically calculate water flow rates for each spray zone and update the fields in the spray zone parameters This feature greatly reduces the amount of time needed to do a simple task such as changing the casting speed or spray pattern of a simulation To be able to use the spray table options the user must first complete a one time procedure to input the spray table data into the interface The procedure can vary in effort needed depending on the format of the users spray table data Figure 3 7 shows the setup of the spray table in the interface 18 Patterns ME Speed Units jain msec Flowrate Units TY gamin Lirrin 1 2 E 4 5 6 162 130 248 320 496 596 596 11 9 12 10 Figure 3 7 Spray Table worksheet setup r Lbckte spray zones fromm spray table Di 177 GP L LO LO C 1 CO l C l On 00 ee Y VR led E Sn Ca III Co ep CO III Dd U Ia ZIAC S ZIEC 12 a The left side of the page requires such information as the number of patterns speeds and zones entered The first column includes the various casting speeds at which spray water flow rates are set at The casting speeds must be copied over for each spray zone Every n number of rows where n is the number of different casting speeds in the table is designated to
103. ther input parameters All parameter descriptions and titles are colored a light green and will turn yellow during the final data check 1f data 1s missing The parameters titles in the outer radius spray zones are colored a darker green so that users can readily tell 1f they are editing the outer radius left side or inner radius right side of the spray zones Page and section titles are bold with a darker blue background to stand out strongly from the page Output data 1s colored a light blue to distinguish itself from the rest of the data The interface also follows a color scheme for the homepage buttons to help guide the user to the next logical step At startup the buttons on the homepage are colored gray They evolve to 13 blue yellow and or green according to a specific pattern to give advice to the user of what to do next Figure 3 3 shows the homepage at startup Compan University of Illinois Name name Mame of input fi CADocuments and Settings User My dina DREI Documents Research Project Examine Output Select All Run Time Messages Cutputs Select Mone vite Input Fil ca Dardan Md Ed Shel Temp Profile Edi shell EN Run COND lala Mach Taper pr Properties Cata Meld Flux velocity Pra Gp oi Sold Fux Bresk Sheer Stress in Gap Fux Temperature Ett Shr Fit A Phase Fractions A Liquid Mese A Liquid Mese Frei Concentraen 1 La Concentracn 2 La r sid Hase m sid Hisse
104. urface 2 g eo E a a E a H Phase Fraction 800 Distance Below Meniscus mm AH Liquid Dea Gamma _ Alpha _ Temp C 10 00mm below surface La Shell Surface 10 20 Figure C 26 Phase fractions out frc for the mold simulation 106 Concentration Time sec Concentration Temperature C vV Nb MES N Temp Distance Below Meniscus mm Time Temp Ml C Si Mn P S ce Ni Cu Mos 0 0513 0 3425 1 5318 0 0123 0 0155 0 0000 0 0000 0 0000 13 80 152019 0 872 00558 0 3505 15695 0 0133 0 0171 0 0000 0 0000 0 0000 14 40 1518 48 0 663 0 0673 0 3604 1 6549 0 0160 0 0215 0 0000 0 0000 0 0000 250 0 15 00 1515 34 0 453 0 0898 0 3950 1 7664 0 0212 0 0313 0 0000 0 0000 0 0000 Zen N 16 AN 1610 Dn n DRA 1990 n 1991 1 026r n 1904 AAG A Pnn A Pnn n Pnn Figure C 27 Liquid phase concentrations 10 00mm below surface out lq1 for full caster simulation 107 Concentration Temperature C 255 Distance Below Meniscus mm Temperature C E G Ke PE ls j E di L E G O Time sec ZDist_ Time Temp fi fa fa C Si Cr x 220 0 13 20 1520 88 0 032 0 032 0 000 0 0098 0 263 0 0000 230 0 13 80 152019 0 128 0 128 0 0001 0 0106 0 269 0 000 240 0 14 40 151848 0 317 0 317 0 000 0 0128 0 283 0 000 250 0 15 00 151534 0 547 0 547 0 000 0 0171 0 3042
105. was ignored by setting the offset to Omm The data for the first five thermocouples is shown in Figure 5 20 The rest of the thermocouple information can be found in Appendix D Offset distance towards hot face 0 00E 00 Total number of thermocouples Distance Thermocouple beneath hot surface Figure 5 20 Thermocouple data for full caster simulation 51 5 3 5 Spray Zones The spray zones are split into two separate pages One page includes the inner radius right side spray zones and the second page includes the outer radius left side spray zones It 1s highly recommended that the user enters the data for the inner radius spray zones page first to enable copying from the inner radius to the outer radius page if they are the same as in this case The spray zone pattern can be chosen as desired if using the spray table to update the water flow rates If using the Leidenfrost effect the user must first enter the number of points on the curve of factors to augment the heat transfer as a function of surface temperature according to the Leidenfrost effect Then the interface creates the appropriate number of white cells to enter in the data To edit the spray zones the number of spray zones must be chosen first This can be done by clicking the Add Delete Zones button and entering in the number of required zones with a maximum of 100 If deleting zones that already exist the program will ask the user which specific zones to delete
106. y 250 0 10 0 50 0 90 0 50 3 36 0 50 Figure D 5b Spray zone properties for full caster simulation 112 Mold Properties Mold Cooling Water Parameters Cooling water temperature at mold top Cooling water pressure Cooling water velocity or flowrate 0 620 MYS Cooling water 8 500 8 500 Cooling water from mad top to bottom amp Cooling water rom mod bottom to top Mold Water Properties Heat transfer coefficient le Default Enter Value Water heat capacity le Default Enter Value Water density le Default Enter Value Mold Geometry Funnel height Funnel depth at mold top Machine outer radius Machine inner radius Narrow face NF mold thickness with water channel 36 000 Equivalent thickness of water box nce Mean temperature diff between hot amp E cold face of NF 1 000 EAN J water channel depth d 20 000 20 000 Cooling water channel width w 5 000 5 000 Channel distance center to center 50 000 22 000 MM 20 000 22 000 Total channel cross sectional area 2300 00 400 00 Mold thermal conductivity 350 000 350 000 MATE Mold thermal expansion coeff 1 60E 05 Figure D 6 Mold properties for full caster simulation 113 Offset distance towards hot face 0 00E 00 Total number of thermocouples Distance Thermocouple beneath hot Distance below 300 0 o 2 1880 TO a 30 1880 3000 2 36 1580 14000 Figure D 7 Thermocouple data for
107. y table and change of units are discussed here A systematic presentation of the complete user interface 1s provided in Chapter 5 3 4 1 Input Graphs A few of the input parameters are tables which can be plotted in graphs to better visualize the data or to compare to experimental data The user interface plots the data in graphs to help the user better see the data they are entering into the simulation Some data entered into CONID are used as parameters in equations to produce a distance or temperature dependent properties The interface plots the properties from the equation from the input parameters automatically An example of this type of graph is entering the average values of mold heat flux A user can enter the average values of mold heat flux on the inner and outer radius and CONID will use the data to create a plot of the heat flux as a function of the distance below the meniscus As can be seen by Figure 3 4 the function that CONID creates in the program is plotted in the interface 15 E gt x E LL LC E 400 600 000 Z distance below meniscus mm Back to Casting Condition Figure 3 4 The plot for the input parameters of average mold heat flux Users can view the heat flux profile and make adjustments to the average values as needed before running the simulation and reading the outputs Another example is the plot of the mold flux viscosity as a function of temperature The mold flux viscosity tak

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